POSIVA 2002 18 Working Report Web

Working Report 2002-18
Experience on grouting
to limit inflow to tunnels
Research and development and case studies from Sweden
Goran Backblom
April 2002
POSIVA OY
T6616nkatu 4. FIN-00100 HELSINKI. FINLAND
Tel. +358-9-2280 30
Fax +358-9-2280 3719
INSINOORITOIMISTO
SAATE
SAANIO & RIEKKOLA OY 4.4.2002
SAATE TYORAPORTIN TARKASTAMISESTA JA HYVAKSYMISESTA
TILAAJA: Posiva Oy
T6616nkatu 4
001 00 HELSINKI
TILAUS: 9672/0 1/JPS, 9522/02/JPS
~~
YHTEYSHENKILOT: Jukka-Pekka Salo Posiva Oy
Reijo Riekkola Saanio & Riekkola Oy
TYORAPORTTI: EXPERIENCES ON GROUTING TO LIMIT INFLOW TO

TUNNELS -Research and development and case studies from Sweden
TEKIJA Goran Backblom Conrox, Taby, Sweden
~-__,;
TEKIJAN PUOLESTA c Iteij~iiekkola Saanio & Riekkola Oy
Toimitusjohtaja
TARKASTAJA Ursula Sievanen Saanio
HYVAKSYJA
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( ~kkola
~
Saanio
~
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T;;ss; ~
- ~
toimitusjohtaja
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I t7'{ ~; 5. f>.- &
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Goran Backblom
April 2002
Goran Backblom
Conrox, Taby, Svveden
April 2002
Working Reports contain information on work in progress

or pending completion.
The conclusions and viewpoints presented in the report

are those of author(s) and do not necessarily
coincide with those of Posiva.
EXPERIENCE ON GROUTING TO LIMIT INFLOW TO TUNNELS
-Research and development and case studies from Sweden
ABSTRACT
This report summarizes results from recent Swedish research and development in
grouting and also experience from grouting operations in tunnels over a range of
geological conditions and a range of sealing requirements.
The objectives of this particular study are !O describe:

The reduction in tunnel water inflow by use of grouting technology
what minimum leakage that can be/has been achieved by grouting?
what grouting materials have been used?
Of special importance is experience from grouting work at greater depths

>> 100 m. Information of leakage reduction during the time of facility operation is also
discussed.
Recent developments in R&D provide a good basis for understanding the process of
cement grouting. Factors like bleed, separation, filtration and penetration is explored.
There are reasonably good models to estimate grout take and grout spread.
The grouted zone will be in the range of 10-7 to 10-9 m/s using a cementitious grout
material, the results being dependent on geological conditions, choice of cement and
methodology used. The inflow of ground water can be as low as around 1 1/min, 100
tunnel-m for a large cement-grouted tunnel (section area 100 m 2) excavated some
10 - 50 metres below the water table. This would indicate a grouted zone in the order
510-9 m/s, but this is certainly no verified value.
Several experts presently favour the use of grout cement that is not too fine-grained.
The very fine-grained cements create practical problems like creation of aggregates. In
the future, the use of colloidal silica in narrow fractures could be an interesting
complement to ordinary cement grouting.
At high water pressures, packer installations are a technical problem to solve, especially
in connection with grouting in poor rock.
Data on groundwater inflow to underground facilities shows a total inflow reduction in

the order of 0.3- 1 %per month. The reasons for these reductions are not understood.
Keywords: Grouting, Bolmen, Aspo Hard Rock Laboratory, Hallandsas, Lundby,

repository, groundwater inflow
KOKEMUKSIA TUNNELEIDEN VUOTOVESIEN VAHENTAMISESTA
INJEKTOIMALLA - Tutkimus- ja kehitystyo Ruotsissa seka kokemuksia
ruotsalaisista tunneleista
TIIVISTELMA
Tassa raportissa kasitellaan viimeaikaista tutkimus- ja kehitystyota Ruotsissa

injektoinnin saralla, seka injektointikokemuksia erilaisista geologisista ymparistoista ja
kohteista, joille on asetettu erilaiset tiiveysvaatimukset.
Tyon tavoitteena on kuvata:

Injektoimalla saavutettuja vuotovesivirtaamien vahenemisia
millaisia minimivuotovesivirtaamia on saavutettu I on mahdollista saavuttaa
injektoimalla
mita injektointiaineita on kaytetty.
Erityista huomiota on kiinnitetty injektointikokemuksiin syvista kalliotiloista

(>> 100 m). Myos vuotojen vahenemista rakentamisen aikana kasitellaan.
Viimeaikainen kehitys- ja tutkimustyo luo hyvan pohjan ymmartaa sementti-

injektointiprosessia. Muun muassa veden ja sementin erottumista, holvautumista ja
tunkeutumista on tutkittu. On kohtuullisen hyvia menetelmia arvioida injektointiaineen
menekkia ja leviamista kalliossa.
Sementti-injektoinnilla paastaan vedenjohtavuusarvoihin K = 10-7 - 10-9 m/s.

lnjektointitulos riippuu geologisista olosuhteista, valitusta sementtilaadusta ja
injektointimenetelmasta. Vuotovesivirtaama pintakallioon, noin 10 - 50 m syvyyteen
louhittuun tunneliin, voidaan sementti-injektoimalla vahentaa jopa noin
11/min/100 tunneli-m (poikkileikkaus 100m2) . Taman voidaan arvioida vastaavan noin
510-9 m/s vedenjohtavuutta injektoidussa vyohykkeessa.
Useat asiantuntijat eivat suosi liian hienorakeisten injektointisementtien kayttoa.

Hienorakeisten sementtien kayttoa rajoittaa kaytonnon ongelmat kuten
paakkuuntuminen. Silica Solin kaytto voi tulevaisuudessa olla hyva injektointiaine
perinteisten sementtien ohessa pienten rakojen tiivistamisessa.
Suurten vesipaineiden vallitessa erityisia teknisia ongelmia voi aiheutua

injektointitulpille, etenkin huonolaatuisessa kalliossa.
Muutamassa kohteessa kalliotiloihin tulevien vesivuotojen havaittiin tyypillisesti

vahenevan noin 0.3 .. . 1 % kuukaudessa. Syyta tahan ilmioon ei tunneta.
Avainsanat: Injektointi, Bolmen, Aspo kalliolaboratorio, Hallandsas, Lundby,

kalliovarasto, vuotovesivirtaama
1
TABLE OF CONTENTS
ABSTRACT
TIIVISTELMA
TABLE OF CONTENTS ..................................................................................... 1
1 INTRODUCTION .. .. .. ... ....... .... .............................. .......... .... .. ..... .... ......... .. . 3
2 STATEMENT OF PROBLEMS ............................................................ ...... 5

2.1 Penetration of saline waters into the repository during the pre-closure
stage .................................................................................... .............. 5
2.2 Mineralogical changes in fractures due to inflow affecting oxygen and
radionuclide retention ........ ... ........... .... ....... ......... ...... ... ......... .......... . 6
2.3 Smooth deposition and backfilling ... .. ................................................ 6
2.4 Safe installation of rock support ............................................ ............. 7
2.5 Environmental effects of the drawdown of the water table .. .............. 7
2.6 Diversion of pumped groundwater .................................... ................. 7
2.7 Cost of handling water ....................................................................... 7
2.8 Impacts during pre-closure operation .................... ........................... . 7
3 PRESENT UNDERSTANDING OF GROUTING ............... .. .. ..................... 9

3.1 Inflow to a tunnel ............................................................. .................. 9
3.2 Geological factors ... ... ................................................. ..................... 13
3.2.1 Strategy for rock characterisation .................................................. 13
3.2.2 Important fracture properties ......................................................... 14
3.3 The behaviour of grouting materials ............................ .. .... ..... ......... 17
3.3.1 Cement-based grouts ....................... ... .. ... ...................... ........ ... .... 18
3.3.2 Non-cementitious grouts ................................................ .......... ...... 20
3.4 Grouting methodology .... .......... ........ ......................... ........... .... ....... 21
3.4.1 Grouting pressure .......................................................................... 22
3.5 Refusal criteria ................................................................................. 22
3.6 Equipment .. ... ..... .. ..... ..... ... .............................................................. 22
4 CASE-STUDIES REVISITED ............ ....... ...... ...... .. .................................. 23

4.1 The Bolmen Water Supply Tunnel ................................................... 23
4.1.1 Project overview ..... .. ....................... ..... ... .. ... ... ........ ...................... 23
4.1.2 Geology ......... ................................................ .. ...... ...... .. .. ......... .... . 23
4.1.3 The requirements .......... ..... ......... ... .... ..... .... .................................. 25
4.1.4 Description of grouting schemes .................................................... 25
4.1.5 Overall results of the grouting operations ...................................... 26
4.2 The Aspo Hard Rock Laboratory ..................................... ........... .... . 29
4.2.1 Project overview ........ ............................. ....................................... 30
4.2.2 Geology ....... .......... .................................. ...... ... ...... ......... .. .. ...... .... 30
4.2.3 The requirements ............ ... ............ ... .... .. ... .. ....... ... .. ...... ... ............ 31
4.2.5 Overall results of the grouting operations .......... .. .......................... 34
2
4.3 The Hallandsasen Railway Tunnel ..................... ............ .... ............. 37

4.3.1 Project overview ............................... ............................ ................. 37
4.3.2 Geology .......................................................... ....... ........................ 39
4.3.3 The requirements .......................................................................... 41
4.3.5 Overall results of the grouting operations .... .................................. 47
4.3.6 Miscellaneous studies ................................................................... 48
4.4 The Lundby Road Tunnel ................................................................ 48
4.4.1 Project overview ............................................... .......... .... ..... .......... 48
4.4.2 Geology ......................................................................................... 49
4.4.3 The requirements .......................................................... ................ 50
4.4.4 Description of grouting schemes ..................................... ............... 50
4.4.5 Overall result of grouting operations .............................................. 50
4.5 Miscellaneous projects .................................................................... 53
4.5.1 Arlanda Railway Project ....................... .. .... ................ .......... ......... 54
4.5.2 The Sodra Lanken Road System ............ ....................................... 54
4.6 Discussion of the cases ................................................................... 57
4.6.1 What tightness can be achieved? .................................................. 57
4.6.2 Grouting procedures ...................................................................... 57
5 DECREASE OF SEEPAGE WITH TIME- FIELD DATA ......................... 61
6 CONCLUSIONS ............................................ ........................................... 63

6.1 The reduction in tunnel water inflow by use of grouting technology. 63
6.2 What minimum leakage can be/has been achieved by grouting? .... 63
6.3 What grouting materials have been used? ...................................... 63
6.4 Experience from high water pressures ............................................ 64
6.5 Decrease of seepage with time ....................................................... 64
REFERENCES ................................................................................................. 65
3
1 INTRODUCTION
To fulfil the needs for detailed design of a disposal system for spent nuclear fuel in
Finland, an underground rock characterisation facility ONKALO will be constructed at
the approved site for the final repository, namely at the Olkiluoto site, (Aikas 2001). All
work will need to fulfil the requirements decided for the ONKALO facility but also the
requirements imposed by the later construction, operation and closure of the final
repository.
One of many concerns in the engineering work is the possible detrimental effect of
seepage of ground water into the underground excavations and methods to mitigate such
effects.
This study is conducted to compile experience on:

What minimum leakage that can be/has been achieved by grouting?
What grouting materials have been used?
At the onset of the study, it was decided of special importance to find experience from
grouting work at greater depths>> 100 m. Also information of leakage reduction during
operation of underground facilities should be discussed.
The results of the study are presented as follows: The Chapter 2 is the preliminary
statement of the problem and what problems the grouting operations are supposed to
solve. The short review of the current state-of-the-art concerning tunnel grouting,
Chapter 3, is helpful background to understand the governing parameters vital for
successful grouting operations for a suite of geological conditions and requirements.
Based on fundamental understanding of the problem and of governing parameters, a few
documented case histories are re-visited, Chapter 4. The first case study is the
experience of grouting of the Bolmen Tunnel, (Backblom 1986a). The second is the
construction of the Aspo Hard Rock Laboratory. This project necessitated new demands
on the grouting process and the work was very helpful to enhance the fundamental
understanding of grouting, (Gustafson & Stille 1996). The road tunnel Lundby in
Gothenburg is an example of a successful sealing operation where grouting resulted in
leakage below 11/rnin, 100 tunnel-m, (Eriksson & Palmqvist 1997), whereas the work at
the Hallandsasen railway tunnel exemplifies a project where grouting operation did not
succeed to meet with requirements, (Rosell 2000). Some comments on the Arlanda
Railway Line and the on-going Sodra Lanken project are furnished before the case
studies are discussed. The following definitions are used for the case-studies. Pre-
grouting is when grouting is made ahead of the advancing tunnel face. Post-grouting is
grouting afterwards, well behind the tunnel face to reduce water inflow, whereas Re-
grouting is when several pre-grouting rounds are made at the tunnel face without any
excavation work at the tunnel section between each grouting round.
4
The Chapter 5 describes decrease of seepage with time for a selected number of
facilities . Chapter 6 summarizes the conclusions of the study.
Banverket, Swedish Nuclear Fuel and Waste Management Co, (SKB) and Vagverket
are acknowledged for the access to unpublished information. In the course of the study
meetings were arranged with the following organizations and persons:
Banverket, Kenneth Rosell

Chalmers University of Technology (CTH), Gunnar Gustafson and As a Fransson
Royal Institute of Technology (KTH), Hakan Stille and Magnus Eriksson
Swedish Nuclear Fuel and Waste Management Co. (SKB), Rolf Christiansson, Peter
Wikberg and Christer Svemar
Vagverket, Region Vast, Per-Olof Eckerlid
Vagverket, Region Stockholm, Eva Widing
The information provided in personal communication is also very much appreciated and
acknowledged as the review by Mr Reijo Riekkola and Ms Ursula Sievanen, both at
Saanio & Riekkola Oy, Finland and the review by Mr Christer Svemar at SKB.
5
2 STATEMENT OF PROBLEMS
This chapter present an outline of problems to be solved by grouting. Inflow should be

reduced so:
the potential penetration of deep, very salty waters to the repository is minimized
during the pre-closure stage,
mineralogical changes in fractures due to inflow affecting oxygen and radionuclide
retention are minimized,
that deposition of canisters and backfilling of tunnels are smooth operations,
that rock support safely can be installed,
the drawdown that might have a detrimental environmental effect at the surface is
limited ~
the diverting of groundwater with possible harmful (salty waters) effects are
minimized,
so the cost of operation during the pre-closure stage is minimized,
so that negative effects on pre-closure operation is minimized.
The problems are outlined in the following.
2.1 Penetration of saline waters into the repository during the pre-
closure stage
Saline waters will decrease the swelling capacity and the swelling pressure of the
bentonite. No swelling can be assured in the low-density backfill when salinity is high,
i.e. several % of NaCl, (Karnland 1997). One concern is that deeper lying saline water
in the coastal condition would up-cone during the pre-closure stage.
The depth down to the saline interface in a coastal environment can as a first estimate be
assessed by the Ghyben-Herzberg equation (Freeze & Cherry, 1997):
2-1
where,
h =the depth of the interface below sea level (m),

P!= the density of freshwater density (kg/m3) ,
ps = the saltwater density (kg/m3) ,
HJ= the elevation of the water table above saline water body elevation (m).
Now, construction and associated drawdown of the freshwater head makes the salt-
water-freshwater interface to up-cone to establish a new hydrostatic equilibrium. Note
however, that in reality there is a transition zone between fresh water and saline water
due to diffusion, changes in recharge, land uplift etc. Also the boundary conditions are
different than assumed in the simplified model described. Swedish experience from
6
Aspo HRL and in the SFR is that much water flows laterally and that up-coning is less
than the Ghyben - Herzberg model calculates. It is imperative to calibrate and run
regional and semi-regional models as one basis for deciding grouting requirements.
Grouting can certainly reduce up-coning, but site management may also contribute in
that the number of open, excavated volumes should be limited. There are also other
technical options available, e.g. to inject water into the bedrock to keep ambient
conditions to the largest extent possible or to completely seal the repository by
watertight linings.
2.2 Mineralogical changes in fractures due to inflow affecting oxygen

and radionuclide retention
Enhanced water seepage in the upper part of the bedrock, caused by the excavation,
could transport oxygenated water into a repository area and reduce the redox capacity of
the bedrock. Experience from the Aspo Hard Rock Laboratory shows that oxygenated
ground water should not reach deeper than - 100 m as long as the amount of organic
matter in the groundwater is larger than the amount of dissolved oxygen, (Rhen &
Backblom (eds.), 1997), (Banwart S. et al, 1994), (Banwart S. (ed.), 1995).
2.3 Smooth deposition and backfilling
Experience from the FEBEX-experiments and from Aspo Hard Rock Laboratory shows
that only a small fraction of seepage will make it difficult to emplace buffer and
backfill.
McKinley ( 1997) reports that air moisture was enough to initiate swelling and break the
bentonite blocks apart. In the actual case also minute leakage from a borehole (less than
a few litres/ 24 h) caused problems. Seepage of 5 1/min over 10 m caused problems to
backfill an experimental deposition tunnel at Aspo Hard Rock Laboratory and it was
needed to divert the water to backfill the tunnel. It might be that all point leakages
> 0.5 1/min need sealing to backfill the tunnels properly.
The smooth deposition and backfilling operation is very essential as unforeseen

technical problems in the pre-closure phase could decrease the stakeholders' general
confidence in repository concept and also the credibility of the people involved to
execute the work.
The problem with seepage can be solved by site selection, site adaptation, selection of
depth for the repository, by freezing, by use of water-tight lining or by grouting. It is
likely that both chemical and traditional cement grouting will be used to reach the
requirements.
7
2.4 Safe installation of rock support
Application of rock support like shotcrete is not possible when excessive water seeps
into the tunnel. Bolts are difficult to grout when water enters the boreholes at pressure.
The problems are well known and can be handled by normal grouting practice and by
selection of bolt systems. An issue is that the hydraulic gradient is very steep close to
the tunnel periphery and water pressures can be several hundred meters only a few
meters away for a typical repository depth. Now grouting will tighten up to the rock and
the gradient will be steeper at the periphery; design of support should take account of
this fact, c.f. (Stille & Olsson 1993).
2.5 Environmental effects of the drawdown of the water table
The anticipated effects should be described. The permits may set the requirements for
permissible drawdown and that in turn will decide the maximum permissible seepage to
the facility. The contact between the soil and rock and the properties of the overburden
is of utmost importance to understand the coupling between seepage and draw down, c.f.
(Olofsson 2001).
2.6 Diversion of pumped groundwater
The diverted water can be much more saline than the surface waters; by limiting the
seepage these problems are minimized. However grouting will increase other types of
problems, as it is difficult to extract all cement spills from the pumped water. The
diverted water will have a low concentration of cement and all additives used for the
grouting purposes. At e.g. the Hallandsas Railway Tunnel Project, see Section 4.3, the
additive RhocaGil and its component acryl amide had a disastrous impact on the
environment and the project. Even when using environmental-friendly products it is a
good idea to find a good discharge recipient. At Aspo HRL the diverted water is mixed
in the outlet water from the nuclear reactor 0 II.
2.7 Cost of handling water
The cost of pumping water from the repository is in fact quite high as the water need to
be lifted around 500 m for a period up to maybe 50 years. In addition to energy cost
there are substantial costs to maintain the main pumps, auxiliary pumps, the pipes and
valves. This costs can be optimised against the cost of more sealing work.
2.8 Impacts during pre-closure operation
The first factor is that seepage of (saline) ground water creates an enormously corrosive
environment and installations should in principle be made by high quality stainless
steel. It is important to cover installations for water drips or to post-grout to reduce the
drips.
8
A second factor of water seepage in the pre-closure stage is that high rate of seepage
makes the properly running pumping system completely vital to avoid any flooding of
the repository. This is an important factor especially when construction and deposition
is concurrent activities.
The third factor is that high water seepage will need big pumping system and these
bigger systems do increase risks for hazardous fires in the underground. The
underground fire scenario is one of the most difficult to handle in safety analysis and all
means should be undertaken to avoid any fire in the repository.
Grouting is useful to minimize the problems addressed here.

9
3 PRESENT UNDERSTANDING OF GROUTING
Grouting is no longer black magic as it was some 30 years ago. The paper by Stille
(1997) is a good historic expose of the development of grouting in Sweden. Knowledge
Systematisation 1977 - 1985 and the Researchers Epoch 1985 - 1993 followed the
Pioneering Period 1966 - 1977. The paper cites 32 references and is overall a good
introduction to Swedish know-how in grouting. Recent progress is described in the 4th
Nordic Rock Grouting Symposium published by SveBeFo (2001).
What is the current understanding of grouting? The short overview here is not an in-
depth study but rather commenting recent progress. The first section is a small
numerical study on inflow to a deep tunnel as a function of depth, tunnel area, hydraulic
conductivity of the original rock mass and the grouted zone to acquire the
fingerspitzgefiihl.
The remaining sections deal with geological factors of importance; the grouting material
the grouting methodology and calculations of grout take and grout spread.
3.1 Inflow to a tunnel
The conceptual model for inflow to a deep, grouted tunnel is depicted in Figure 3-1-1 .
A deep, grouted tunnel will as a simf,lified model c.f. (Brantberger et al 1998),
equation 3-1 experience the inflow Q (m Is, m) as
h
Darcv's law
CA t
K~ K
Figure 3-1-1. Conceptual model for inflow to a deep, grouted tunnel.

10
27r K h
Q= l 3-1
(R+tJ
In - - + -K In - - (2hJ +;
1
R K R+t
where,
Q =inflow to the tunnel per metre of tunnel (m3/s, m),

Ki =the hydraulic conductivity of the grouted zone (m/s),
K =the hydraulic conductivity of the rock mass outside the grouted zone (m/s),
R =radius of tunnel (m),
t = extension of the grouted zone (m),
~=skin factor (-)accounting for the pressure fall at the tunnel periphery.
For the un-grouted tunnel the inflow Q per meter tunnel is (Equation 2-2 in Brantberger
et al, (1998))
3-2
The skin factor is an empirical value. Measurements at Aspo HRL showed a value of
4-7 (Rhen et al 1997).
The effect of grouting is now illustrated for a choice of parameters to receive a

fingerspitzgefiihl for the formulas .
Suppose for all cases that the tunnel is 450 m below the groundwater table, the tunnel
radius is 2.5 m. The hydraulic conductivity of the rock mass is 10-8 m/s as the reference
value. Skin factor 5 is used as reference value; the influence of the skin factor is shown
below in Table 3-1-1 . It should be of value to study how the skin factor is influenced by
method of excavation as the skin zone itself reduces - 50 % of the inflow.
The inflow for a range of tunnel areas is shown in Table 3-1-2. It is understood the
inflow is not so sensitive to the area of the tunnel. Now suppose the rock is somewhat
conductive (K = 10-7 m/s) ; what can grouting accomplish to limit the water ingress
(Table 3-1-3)?
11
Table 3-1-1. Influence of the skin factor (Equation 3-2); h = 450 m, R = 2.5 m,
K =Jo-Bmls.
Skin factor Inflow Q to tunnel

(-) (1/min 100 tunnel-m)
0 28.8
1 24.6
2 21.5
3 19.1
4 17.2
5 15.6
6 14.3
7 13.2
8 12.2
9 11.4
10 10.7
Table 3-1-2. Influence of tunnel area on the inflow (Equation 3-2); h = 450 m,
K = 1 o-B m/s, ~ = 5.
RADIUS Inflow Q to tunnel

(m) (1/min, 100 tunnel-m)
1 14.4
2.5 15.6
5 16.6
10 17.8
Table 3-1-3. Inflow to tunnel for different hydraulic conductivity of the grouted zone
and extension of the grouted zone.(Equation 3-1); h= 450 m, R = 2.5 m, ~ = 5, K = 10-7
m/s.
Conductivity Ki for Inflow Q to tunnel

the grouted zone for (1/min, 100 tunnel-m)
a range oft-values
Ki =10"8 m/s
t = 2.5m 27.3
= 5.0m 25.8
= 10m 24.1
=25m 21.9
Ki =10" m/s
9
t =2.5m 3.0
=5.0m 2.8
= 10m 2.5
=25m 2.3
12
It is obvious that the achieved hydraulic conductivity by grouting is much more

important for inflow reduction than the extent of the grouted zone.
There is a common definition for the sealing efficiency Serf as
Inflow requirement after grouting

Sealing Efficiency= 1 - - - - - - - - - - - - - 3-3
Inflow without grouting
Suppose the requirement is to have water ingress below 3 1/min, 100 tunnel-m. The
required sealing efficiency is shown in Table 3-1-4.
Finally, let us assume that we have first-class grouting and reach a grouted zone
hydraulic conductivity of 110-8 m/s; what is the effect of the overall hydraulic
conductivity of the rock mass? The results are shown in Table 3-1-5. It might come as a
surprise, but the inflow is to a less degree dependent on the ambient rock conditions.
In summary: The fingerspitzgefiihl is really that the overall important factor for
controlling the inflow is the hydraulic conductivity of the grouted zone. This
conductivity is far more important than the area of the tunnel, the grouted distance, the
skin factor and even the ambient rock mass conductivity. It is thus of overall importance
to adapt the grouting material and grouting technology to the prevailing conditions and
also to ensure that the subsequent excavation do not damage the grouted zone.
Table 3-1-4. Required sealing efficiency for inflow below 3 1/min, lOOm tunnel-m
(Equation 3-1); h = 450 m, R = 2.5 m, (= 5, t = 5m.
Hydraulic conductivity K Inflow Q to tunnel without Required sealing

of the rock mass grouting (Equation 3.2) efficiency
(mls) (Vmin, 100 tunnel-m) (%)
1 109 1.6 Sealing not necessary
1 10"8 I 16 I 80.7
1 10"7 155 98.1
1 10"6 I 1560 I 99.80
Table 3-1-5 Influence of original rock mass conductivity on the inflow (Equation 3-1);
h = 450 m, R= 2.5 m, (= 5 , t=5m, K; = 10-8 m/s.
Hydraulic conductivity K Inflow Q to tunnel with grouting

for the rock mass (Equation 3-1)
(mls) (Vmin, 100 tunnel-m)
510 -S 24.0
110 "7 25.8
510 - 7 27.4
110 "6 27.6
13
3.2 Geological factors
This section deals with geological factors that will control the inflow and the results of
the grouting operation. The Doctoral Thesis by Fransson (200 1) makes the simple
hypothesis that fracture aperture, orientation, spacing and length (or area) are the most
important material parameters for fracture flow. A typical conceptual model for a
conductive structure is presented in (Winberg et al, 2001 ). Since the aim of grouting is
to reduce flow, the parameters of importance to describe flow are also likely to be of
significance as well. First we discuss a possible strategy for rock characterization.
3.2.1 Strategy for rock characterisation
The objectives for the work by Fransson, (2001) was to establish a characterisation
methodology with for basic qualities:
consistent throughout all stages of the project,
based on a reasonable amount of tests and data,
it should facilitate the choice of strategy as e.g. the drilling pattern and what grout to
use,
it should enable predictions of grout take, penetration lengths and result of
application.
The suggested strategy is shown in Table 3-2-1 . Based on analytical and numerical
studies it was found that the normalised grout take is very well correlated to the
transmissivity, the quotient being 1-2. The specific capacity Q/ ~h was proved to be a
good measure of the transmissivity. When a fracture close to a borehole is narrower
than at a distance, the local hydraulic aperture is controlled by the conditions close to
the borehole. In the reverse conditions, interpretations are biased also of the aperture at
a distance.
The following promising general conclusions in (Fransson 2001) are:

the specific capacity Q/ ~h derived from short duration hydraulic tests is robust ,
enough to describe fracture aperture for grouting purposes,
a small number of hydraulic tests are enough to give a general picture of a fracture ,
probe holes are useful for interpreting data from individual boreholes (e.g. grouting
boreholes) and for improving predictions,
data obtained along individual boreholes using hydraulic tests and geological
mapping may be used and linked to form as simplified 2.5 D-model that is robust
enough for an engineering problem, such as grouting.
14
Table 3-2-1. Suggested field strategy for characterisation offractured rock for grouting
(Fransson (2001).
Scale Investigations/ Obtained parameters Influence on grouting strategy

Input data
Tunnel Geological mapping Orientation of fractures Orientation of boreholes (increases
situation probability of crossing fractures)
Grouting Distribution of fracture lengths Distance between probe holes

(improves predictions for grouting,
fan information about intermediate fractures)
Tunnel Grouting borehole Correlation length from variogram Distance between probe holes
analyses of specific capacity, Q/~h and
situation -specific capacity Q/~h
borehole distance
A measure of connected
fracture length/size
Tunnel Probe hole Probability of conductive Groutable fractures
situation fractures, Pc Grout take
-Fixed interval Transmissi vity distribution
transmissivities Tj 0(p ), from non-parametric Grouted volume V - transmissivity, T
-Fracture frequency method
Inflow Q (if no grouting) - T-h
-Hydraulic head, h Aperture distribution b(p ).
Penetration length I
I - aperture, b
Overview of the rock ahead of tunnel, initial

description of sections according to
transmissivity distribution 8(p), which is also
used for analyses of grouting borehole data
Grouting Grouting borehole Probable number of conductive Estimate inflow,
Q ::::: Th
fan -Specific capacity fractures. Intervals or
What fractures need to be/can be sealed.
-Fracture frequency distributions of specific
-Probability of capacity (Q/dh :::= T) and Guidance when choosing type of grout and
conductive fractures , Pc aperture. additives.
-Transmissi vity Hydraulic head
distribution, 0(p). Grout take V
V- T :::= Q/Ml
Penetration length I
I- b
3.2.2 Important fracture properties
Aperture
For the crystalline rock, the major bulk of water is transported in the open fractures . The
open fractures constitute a small part of the fractures in the rock mass. Whereas the
individual fracture aperture is log-normally distributed it is also expected that all
fracture aperture of all fractures also be log-normally distributed. The flow q in an
individual fracture is correlated to the aperture b in cubic, i.e. q . . . b 3 and it thus follows
that the major part of the flow is transported in the few fractures that are the widest.
From a grouting perspective this is good as the higher aperture fractures should be
easier to seal. However, if the requirements are really low inflow then also the very
15
many, but very narrow fractures need to be sealed. The report (Brantberger et al 1998)
elaborates on these facts and illustrates what fracture apertures needs to be sealed to
achieve flow, for three different lognormal fracture aperture distributions, Table 3-2-2.
Suppose the distribution 2 (many fine fractures) represents a form of geological crush
zone. It is obvious that very fine fractures (< 0.07 mm) will have to be sealed to reduce
the hydraulic conductivity to less than 510- 8 m/s.
The studies by Eriksson (2001a) show that standard deviation of aperture is a very
important factor for apertures < 100 J..Lm, but not important for fractures with apertures
>200 J..Lm.
Fracture roughness
For the situation when the fracture plane is undulating, it is also needed to know how
large a portion of the fracture plane that actually will be completely filled as a function
of the particle size. For a coarse fracture, 1.00 mm this factor is not important. However,
the factor is of importance when fractures are fine. Based on certain assumptions the
following proportions of a fracture plane will be filled with cement, Table 3-2-3. The
obvious conclusion is that it is really very difficult to completely seal fine fractures.
The studies by Eriksson (200 1a) show that amount of contact is a very important factor
for apertures < 100 J..Lm, but not important for fractures with apertures > 200 J..lm.
16
Table 3-2-2. Flow reductions when sealing down to a certain fracture aperture
(Brantberger et a/1998).
Fracture K before 90 % reduction K (90%) 99 % reduction K (99%)

distribution grouting necessitates after necessitates after
sealing of grouting sealing of grouting
fractures down to fractures down to
(rnls) (mm) (rnls) (mm) (rnls)
Base case
Max aperture
l.Omm
Min aperture
5.310-6 0.40 5.310-7 0.14 5.310-8
0.1
Fractures/m
0.1
Porosity (%)
0.0036
Many fine
fractures
Max aperture
0.5 mm
Mi n aperture 5.310-6 0.20 5.310-7 0.07 5.310- 8
0.05
Fractures/m
0.8
Porosity(%)
0.0143
Few coarse
fractures
Max aperture
2.0 mm
Min aperture 5.310-6 0.8 5.310-7 0.29 5.310-8
0.2
Fractures/m
0.0125
Porosity (%)
0.0009
17
Table 3-2-3. Proportion of fractures that will not be sealed as a function of cement
grain size. For assumptions, see Brantberger et al (1998).
Cement grain size (Jlm) 8 112 116 130 164 1120

Fracture width (mm) 1.00
% not filled volume 0.06 I o.12 I o.22 I o.1s 13.56 112.60
% not filled volume 22.52 I 51.21 I 92.oo I 1oo.oo I - I-
% not filled volume 63.45 11oo.oo I- J- I- I-
Fracture infillings
The grouting of a fracture zone (Test 4) at the Strip a mine is further illustrating the
point, (Pusch 1992). The fracture zone of "3rd order" has the hydraulic conductivity of
around 10-8 m/s and grouting was made by applying "dynamic" injection technique
using a static pressures of 1 - 1.5 MPa and an oscillating frequency of 40 Hz. Grouting
material was Alofix cement with maximum grain size of 15 J-Lm, water-cement-ratio of
0.45 and 1.4 % super-plasticizer Mighty 100. The overall results showed a ten-fold
decrease of hydraulic conductivity down to - 10-9 m/s. The hardened cement was
sampled by core-drilling into the fracture zone. Thick cement fillings> 30 J-Lm appeared
to be of high density and high degree of micro-structural homogeneity. However,
infillings of 10 - 30 J-Lm showed variations in density and structure, while fractures with
cement filling < 10 J-Lm were very porous and heterogeneous. It was thought they were
brought in place not by injection but by precipitation of compounds released from more
dense cement patches. The report (Pusch 1992) finally concludes concerning Test 4, that
all the channel space with less aperture than 30 J-Lm can be taken as unfilled and this is
consistent with the hydraulic conductivity of 10-9 m/s of the grouted zone.
Another factor discussed in Pusch (2000) is the factor of fracture infillings. He states,
"One of the most important experience at Stripa was that practically no bentonite- or
grout penetration occurred in natural fractures, only in fractures caused by blasting ".
Cement grout material cannot push fracture fillings like quarts, epidote and calcite.
However clastic fracture infillings as clay, mica and chlorite could be pushed by the
cement or bentonite grout and thereby clogging the fracture opening at high grouting
pressures. The penetration by the grout is supposed to be too limited. Pusch (2000) thus
concludes that effective sealing of fine fractures in infillings only is successful using
chemical grouts.
3.3 The behaviour of grouting materials
Grouting materials are either cement-based or non-cementitious. While most work has
been on cement-based grouting material this study is focus sed on this application.
18
3.3.1 Cement-based grouts
The paper by Fjallberg & Lagerblad (2001) gives a process- and data overview of the
cement-paste, additives, fillers , accelerators, retarders and super-plasticizers for the
purpose of grouting. Experiments show that results are very varying depending on type
of cement, superplasticizer, water-cement ratio, temperature etc. so optimisation of the
mixture is essential.
Grain sizes and specific areas for cement grouts are in the range of 6- 120 JJm and
300-2000 m2/kg in depending on choice of commercial cement, see Table 4-1 in
(Brantberger et al 1998). Brantberger et al (1998) has also compiled expert opinion on
groutability, Table 3-3-1.
Generally accepted "rule of thumbs" for standard cement seems to be apertures

> 0.1 mm are groutable and aperture/cement grain size ratio should be > 3 to facilitate
penetration and to mitigate filtration.
Penetration, filtering
Filtration is the process where the grout material clogs at a constriction in the flow path.
Based on numerical studies (Eriksson 2001 b) it is obvious that there is a significant
change in grout-spread stop when the flow is subjected to filtration due to limited
penetration ability. For good grouting results it is important that the grout is low viscous
and has high penetrability, especially for fracture apertures< 100 J.lm, (Eriksson 2001 b).
Field tests have also been executed (Dalmalm & J anson 2001) to test e.g. the filtration.
The requirement imposed, was that filtration stability was to be measured with a filter
pump. One hour after mixing, at least 300 ml should be able to pass a 125 J.lm filter.
The following sealing efficiencies wereobtained in field tests, Table 3-3-2:
The authors note that filter pump values did not correspond between the laboratory
work and the field work and concludes that this is due to poor dispersion in the field
mixer. In the field tests sealing were achieved as far from the tunnel periphery as 10 m.
They also conclude that:
joints with hydraulic aperture of 0.1 mm or less were not possible to seal, even using
a microcement (9.5 JJm)
based on records of dampness and droppings, the microcement outperformed other
cements
Lugeon sums below 0.3 (- 310-8 m/s) only resulted in hole filling for the grouting
pressure 20 bars
microcement seal better for Lugeon > 0.5 as the microcement fill the fracture better
than ordinary cement
for tight rock masses and ordinary equipment, microcement do not perform better
than ordinary grouting cement.
19
Table 3-3-1. Expert opinion on what fractures that can be sealed (Brantberger et al,
1998) and Table 4-4 I Hansson 1997).
Reference Note Fracture aperture Aperture/cement

(mm) grain size
(Kutzner 1996) Normal cement grout
operation, stable grout 0.1
mixes
(Bergman & Nord 1982) 3-5
(Bogdanoff 1990) 2
(Pusch 1991) Dmax 16 f..!m, dynamic
0.02
grouting
(Pusch 1993) Cement grouting 0.05-0.1 1.25
(Hansson 1994) Dts for soil, ds 5 for the
D1s/dss ~ 25
grout mix
(Hansson 1994) Rule of Thumb 3
(Hansson 1997) Cement grouting 0.15
(Melbye 1993) Microcement
0.25-0.3
Rheocem 900
Table 3-3-2. Sealing efficiency Seff (%) in 7 field test groutings (Dalmalm & Janson
2001, Brantberger et al1998).
Rheocem Cementa Inj 30 Cementa Inj 30 RockU

Microcement Grouting pressure 25 bar High grouting pressure Microcement
Max size 30 fJffi (D9s) 45bar
Max size 15 fJm{D97) w/c 1.0
1300 (BET)
Fan 820m2/kg Compound B 4%
w/c0.6
w/c 1.2
HPM0.7 %,
Rheobuild 1.4 %
2% accelerator
Seer(%) Serr(%)
Seer(%) Serf(%)
1 100 45
2 31 76
3 48 28
4 92 10
SA 13 24
SB 44 34
6
Mean 66 49 29 40
20
Experiments by Eklund & Alemo (200 1) show that the cement grout should have few
fine particles < 5 Jlm and few coarse particles. Particle size distribution and water-
cement ratio both strongly influence the rheology and the filtration stability.
The keynote paper by Stille, (200 1) explains that the commercial cement product with
grain sizes down to 30 Jlm makes it possible to grout apertures down to - 100 Jlm.
However finer cement, down to 16 Jlm does not improve penetrability as the cement is
more reactive and the penetrability decreases rapidly after mixing.
Bleed
High water-cement ratio results in bleed, i.e. separation of cement and water. There is
an ongoing trend to grout with stable grout. The definition of a stable grout is a grout
where the separated volume of water is less than 2 % of the total volume after 2 hours of
testing. The rheological properties of the grout is very dependent on proper mixing and
using a colloid mixer with 1450 rev/min, the mixing time should at least 2 - 4 minutes
accordingly to Brantberger et al (1998). Modem grouting utilizes super-plasticizers.
Due to the rapid aging, the grout should be made in small batches. Recent work by
Eriksson (200 1b) shows that low bleed is a very important factor when fracture
apertures > 200 Jlm, but not important for fracture apertures < 200 Jlm.
Grout spread and grout volume
Grout spread and volume can be assessed as (Hassler, 1991):
2
V=l b N -
a 3-4
2
pb
l=-- 3-5
2 To
where p is grouting pressure at zero grout flow, V is volume of grout at zero grout flow,
b is aperture of open section in the fracture plane, I is grout spreading distance, 1:0 the
yield value of the grout, N is number of grouted fractures and finally a. the spreading
angle.
The spreading angle a. can be tied to the Rock Mass Rating (RMR)-value as described in
Table 3-3-3). The work by Eriksson et al (1999) and Eriksson et al (2001c) evidence
that there are reasonably good models to predict grout take and grout spread.
3.3.2 Non-cementitious grouts
Chemical grouts have been more thoroughly discussed in the PhD thesis by Andersson
(1998) particularly on the properties of the polyurethane foams. One interesting
statement in her review is that volume expansion ceased at 0.6 or 1.6 MPa for the two
21
Table 3-3-3. Choice of spread angle a. for at range of RMR-classification

(Janson 1998).
RMR-value RMR-classification Spreading angle a

radians (de rees)
100- 81 Ver ood
80 - 61 Good
60-41 Fair 0.4 (44)
40 - 21 Poor
different polyurethanes isocyanate and polyol. Bogdanoff (1990) reported also results of
expansion tests. In the laboratory he found that TACSS did not foam for pressures over
0.18 MPa using sand column tests. However at repeated tests up to 0.7 MPa it was
shown that gel creation do start in the sand, but not on top at the primary section in the
column. He also showed that the magnitude of volume expansion is 10 - 15 under
atmospheric conditions, but down to 2 - 4 when pressurized.
Recently, Swedish studies are in progress to use colloidal silica as a grouting material.
The material is a stable dispersion of discrete amorphous particles of silicon dioxide. pH
is in the range 4-12, particle size 4 - 100 nanometers and viscosity in the order of
5 - 50 mPas at 25C . Surface area is 80 - 500m2/g. More information is available e.g.
at www .ekachemicals.se/csgrp/index.html. The material is pending patent. A quick
Internet search revealed that similar materials have been used extensively for grouting
of soil.
Bentonite was tested as grout in the Stripa Project, (Pusch 1992). Bentonite grout with
optimum penetration/sealing properties can enter fractures down to 20 Jlm. Penetration
length is ~ 5 m for a 300 Jlm aperture and down to 0.5 m in a 30 Jlm fracture aperture.
The use of non-cementitious materials needs a strategy to environmentally qualify the

grout before application. Hartlen (200 1) has suggested a strategy that is in use at some
current Swedish tunnel projects. The grout and additives used shall be evaluated
accordingly to the of Act on Environment and the regulations by the Chemical
Inspectorate.
3.4 Grouting methodology
Grouting methodology encompass a suite of choices that so far not have been treated
scientifically. Issues are e.g. single hole or multiple-hole grouting, what holes should be
grouted at first, how should grouting material properties etc. be changed during
grouting. Promising work is however in progress. Eriksson (200 1b) reports that high
grouting pressure, low minimum flow and small distance between grouting holes are
essential parameters for fracture apertures < 100 Jlm, but not important for apertures
22
> 200 J.!m. High maximum volume during grouting is very important for fracture
apertures > 200 J.tm but not important for apertures < 100 J.tm.
In this review, we focus on the issue of grouting pressure and refusal criteria. Other
matters are also shortly discussed in Chapter 4.6.
3.4.1 Grouting pressure
One issue of concern is that the grouting will create new fractures due to high grouting
pressures. Based on experience from dam grouting, the risk for hydraulic uplift can be
determined by Brantberger et al, (200 1):
3-6
where Pn is the normalised pressure and Vn the normalised volume at different

apertures b.
3.5 Refusal criteria
Stille (200 1) argues that refusal should be studied further. There are many refusal
criteria in use, but they are all based on empirical experience and very little on
theoretical considerations. The theoretical understanding of grout spread could be used
to develop better rules.
3.6 Equipment
As noted previously, the equipment is very important. In Pettersson (2001) there is a

historic overview of development of equipment. With respect to mixing, best mixing
speed is around 1700 - 1800 rpm for normal batches. It is however a concern that
mixing in laboratory and mixing in field does not give the same results when measuring
e.g. filtration stability (Dalmalm & Janson, 2001). Ellison & Hjertstrom (2001) argue
that penetration-properties are equal for laboratory-prepared cement grout and grout
under realistic production conditions based on experiments for equipment used in a
recent tunnel project.
--1
23
4 CASE-STUDIES REVISITED
This chapter presents selected cases where grouting has been an important part of the
underground work. The selection is based on availability of information, own
experiences and also for cases where special developments in grouting were made.
The first case - the Bolmen water supply tunnel - is a 80 km long tunnel, - 8 m 2 in area
that was excavated in a broad range of rock conditions and where the requirements on
groundwater impact were not very high. The second case - the Aspo Hard Rock
Laboratory - is interesting, as grouting is made at water pressures similar to the
pressures anticipated for a final repository. The need to integrate site characterization
and construction also imposed new requirements, as the grout spread was to be limited.
The Hallandsas Railway Tunnel is parallel tunnel to the Bolmen Tunnel through the
Hallandsas horst, but excavated in a much more disturbed part of the horst. The
requirement for low seepage is quite high, but the client did not succeed to keep up with
the requirement and the project later evolved into a technical, environmental and
political national issue. The last case referred to is the Lundby tunnel where the client
achieved very high demands for tightness< 1 1/min, 100 tunnel-m. Some miscellaneous
projects are finally commented.
The cases are more or less discussed chronologically spanning over a period of close to
20 years. The last section of this chapter is devoted to a summarised discussion in
relation to the goals of this project.
4.1 The Bolmen Water Supply Tunnel
The Bolmen Water Supply tunnel was a major project over a period of 25 years to
ensure that the Skane region had a supply of water. The book by Reingardt (1991) is an
excellent reading on the project. The work by Backblom (1986a) and Backblom (1986b)
is directly connected to the experience of the 2500 groutings over the length of the
tunnel.
4.1.1 Project overview
The 80 km long Bolmen tunnel was constructed to divert water from the Lake Bolmen
down to the more densely populated Skane area. Construction of the Sydvatten system
started 1975 and was completed 1987, c.f. Figure 4-1-1 The Figure 4-1-2 shows the
topography, and the tunnel depth below surface and grouting performed.
4.1.2 Geology
The Bolmen Tunnel is situated in the southwest part of the pre-Cambrian bedrock. The
bedrock is gneissic with inclusions of amphibolites as dykes or as massif formations.
Diabase dykes are common in the south part of the tunnel. The part of the region that
the tunnel passes is almost completely covered by overburden. Extensive pre-
investigations were conducted to design the stretch, to engineer the tunnel and to
24
calculate the investment costs. The tunnel passes several important geological major
fracture zones, like Hallandsas, Lagan Valley and the Staverhult zone, (Backblom &
Stanfors 1986).
Fork/a ring:
Bergtunnel
Ravattenledning
Renvattenledningar
Anlaggningar

Figure 4-1-1. Overview of the Sydvatten water supply system. The Bolmen Tunnel
"Bergtunnel" is around 80 km long (Reingardt 1991).
25
o~.....-.....
20G 1
II.
ISO
100
40 so 60 70 I Oiao
% GROUTED I
1000
soo
KG/GROUTED TUNNEL m
Figure 4-1-2. Overview of the grouting work (Biickblom 1986a).
4.1.3 The requirements
The grouting work should mitigate damage by drawdowns, possible poor water quality
due to seepage of groundwater and limit water losses from the tunnel during operation
stage. At the onset of the work 9 1/min, 100 m were thought to be a reasonable demand.
(The requirement was a tenfold increase compared to the demands in the Stockholm
region.) Due to contractual claims the requirement in 1981 changed to
- 42 1/min, 100 tunnel-m. For the second general contractor contract (24 km of tunnel)
the requirement on grouting was to make tunnelling feasible.
4.1.4 Description of grouting schemes
The description is mostly related to the 2nd building contract for the last 24 km of
tunnel.
Probe holes
Probe holes were drilled "when considered necessary" with hole lengths more than three
rounds and inclined 15 with the centre line.
26
Water- loss measurement
For the 1st contractor contract (56 km) measurements were conducted at an overpressure
of at least 0.2 MPa. Grouting was to be conducted if water losses were more than
3 1/min, m, MPa over pressure. For the 2nd contract water-loss measurements were
replaced by ocular inspection of probe holes 1 = drip 2 = flow 3 = spurting and grouting
was made for flow or spurt. If water was encountered at the first drilling rod some extra,
short holes were drilled at as much angle as possible.
Grouting
Grout holes were to be flushed by a pressure of at least 1.2 MPa. Grouting was mainly
by cement + bentonite starting at water-cement ratio w/c = 3 and then down to 2.1 and
0.8 after respectively 10 minutes, 10 minutes, 20 minutes and w/c = 0.8 for ten minutes
and at last w/c 0.5 to stop pressure at 2.5 MPa. Several holes could be grouted in
parallel if the equipment had separate flow measurements for each hole and drilling of
the holes for the blast round could begin 5 hours after grouting work using the standard
cement.
Grouting material
The client and the contractor for the 2nd contract set the objective that drilling, grouting
and removing packers should be finished within an 8-hour shift. The contractor
developed a mix of cement, bentonite and silicates and after lab and field-tests the
material worked out nicely with few re-groutings. The grout is called Bolmenbruk or
StabiloGrout.
Blasting
Smooth blasting with Gurit 17 in periphery and in helper holes was used at the grouted
sections.
4.1.5 Overall results of the grouting operations
In total 2567 groutings were conducted and 25 % of the tunnel is grouted. The average
grout take is 125 kg cement/tunnel-m. The total average inflow to the tunnel is 43 1/min,
100 m, which can be translated to an average hydraulic conductivity of 0.810-7 m/s
(Backblom 1986b) for the grouted tunnel. Backblom ( 1986b) also evaluates the stretch
39/056 - 39/485 where grouting was continuous for almost 500 m. At this stretch the
fractures are perpendicular to the tunnel and relatively open. For this stretch the
conductivity was deemed to be in the order of 21 o-7m/s before grouting and based on
water-loss measurements. The seepage after excavation translates to a hydraulic
conductivity of 10-8m/s for the grouted zone. (Based on re-calculation with zone of
extension, t = 1Om) The grouting at this stretch reduced the inflow a factor of 7 to the
measured 150 1/min from the 1 100 1/min likely to seep without any grouting,
corresponding to the sealing efficiency 83 %.
27
--
The 2567 groutings were analysed and a simplified picture was developed to understand
where groutings are easy and where grouting operations are difficult. The simplified
presentation is shown in Figure 4-1-3. In the horizontal direction is the simplified
fracture infilling situation and in the vertical direction the fracture geometry situation.
Now starting with the simplest situation, the fractures being open and perpendicular to
the centre line of the tunnel; this situation in general do not possess any major problems
to completely seal. As the fractures are in plane strain, high grouting pressure should not
either be a problem. Now consider the same geometry, but with gouge filled fractures.
At Bolmen the infillings in fractures are clay and sandy material and do not require
chemical grouting materials. 150 clay samples showed that the clay fraction< 2 !Jm was
less than 20 %. A problem encountered, was that the material flush out and new
pathways are created when grouting pressure increase at the end of the grouting
operation. The mix of open and gouge-filled fractures is however problematic. The crew
experiences big grout takes and later an increase in pressure and subsequently end the
operation before the gouge-filled fractures are grouted. The result can be that re-
grouting is necessary. The situation with horizontal fractures creates technical problems,
especially at high water pressures. Typical problems are to really seal the vertical main
conductor, leakage at the tunnel face, deformation of the rock mass during the grouting
and the difficulty to check the results of the grouting.
TYPE 0 F JOINTS
JOINT
DIRECTION
VERTICAL,
PER PEN 01 CU LAR rr-r-s..,-,-r-r-r-....--H~
HORIZONTALX)
r- -2------ __E
e) f)
LLLlll I I
I
Ll Ll l l
I
g) h)
x)
EQUIVALENT TO 1 STRAIGHTFORWARD 3 DIFFICULT
VERTICAL, PARALLEL 2 MODERATELY DIFFICULT 4 VERY DIFFICULT
Figure 4-1-3. Simplified sketch summarising easy and difficult grouting operations
Biickblom (1986a ).
28
When the hydraulic conductors are parallel with the tunnel they are very difficult to hit
during drilling and these features really are a problem to seal in small tunnels where it is
difficult to vary the direction of the drilling equipment.
When fractures are in many directions the problems with leakage and tightness around
packer increase substantially; also the deformations increase; here the question of
grouting pressure is essential. Backblom (1986b) refers to other hydro-mechanical
studies showing that the blocks move during the grouting operation and that joint
apertures became so small that they essentially closed the flow of water. In other words,
water only move along the central fractures that intersects the well bore but not the rest
of the rock mass. Along the "rainy area" at Work Site 17, water flowed or flushed out of
the probe holes, but no water-losses could be recorded in the tests.
Another factor studied was the situation after grouting; the rock is sealed under a certain
stress state and after excavation a new stress-state is created. These factors were studied
with the help of simple, elastic finite element models. The general idea was to study the
unloading of the rock. First suppose the fractures are vertical and in direction parallel to
the centre line of the tunnel, Figure 4-1 -4. The figure shows then the un-loading in the
horizontal O'x-direction for the condition that the primary horizontal stress doubles the
vertical stress.
OHREAS[
IN 0)(
c=:::J > 10 %
~ > 25 %
- >~0 %
Figure 4-1-4. Un-loading of stresses zn x-direction after excavation

(Biickblom1986a ).
29
OC REASE
IN Gy
c::::::J > 10 "/ o
m.m > 15"/.

- >SO "/.
Figure 4-1-5. Unloading of stresses in the y-direction after excavation

(Biickblom 1986a ).
The figure illustrates that there is more than 25 % of crx-decrease about the same width
as the tunnel dimensions. The Figure 4-1-5 illustrates the same stress situation as in the
previous Figure 4-1-4, but assuming unloading in the horizontal fractures .
While grouting is performed prior to the stress un-loading it is really important that the
grouted zone extends beyond the zone of un-loading, i.e. grout spread should be at least
in the same order as the width of the tunnel.
At the Bolmen tunnel it is estimated that - 75 % of the inflow is from the floor of the
tunnel. How much can be attributed to the heavy blasting in the tunnel floor?
4.2 The Aspo Hard Rock Laboratory
There is an abundance of information regarding the Asp6 Hard Rock Laboratory. The
publication SKB (1996) provides a good general overview, the report Rhen et al (1997)
the overview of the site conditions and Hamberger (1993) and Hedman (1999) about the
engineering aspects. All these references are concerned with the pre-construction and
the construction stage. References related to grouting are e.g. (Stille et al 1993), (Stille
et al 1994), (Backblom & Svemar 1994), (Gustafson & Rhen 1995a,b), (Gustafson et al
1996) and (Fransson & Gustafson 2001 ). While the project is quite well known, less
effort is made to duplicate general available information.
30
The Aspo Hard Rock Laboratory is an underground facility to develop and test
scientific and technical issues before implementation at the future deep repository for
spent fuel in Sweden. The re-investigation stage lasted 1986 - 1990 and the
construction stage 1990- 1995. The operation stage started 1996.
Essential goals 1986 - 1995 were:

to demonstrate that investigations on the ground surface and in boreholes provide
sufficient data on essential safety-related properties of the rock at repository level,
to refine and verify methods and technology needed to characterize the rock in the
detailed underground characterization.
A strategy was formed for the site investigations and for how to verify the investigations
(Backblom 1998) and this strategy of course had impacts on engineering and
requirements on groutings. Construction was carried through in parallel with data
collection. Excavation was mainly by drill and blast and with a TBM for parts of the
facility. The requirements also led to development in understanding of the grouting
mechanisms.
4.2.2 Geology
Two different granitoids dominate, the Smaiand granite and the Aspo diorite.
Greenstone, (5 %) old volcanic rocks and fine-grained granites (15 %) make up a minor
part of the bedrock. The area is penetrated by NE- ENE- EW oriented fracture zones
and swarms of NNW-NNE-trending minor fracture zones that also were good hydraulic
conductors. Maximum principal stress is oriented NW and the horizontal stresses
dominate over the vertical.
The hydraulic model is stochastic with discrete hydraulic conductors. The average
hydraulic conductivity is in the order of 110-9 m/s for test length 3 m. Average
transmissivity for discrete fracture zones is the range of 110-7 - 110-4 m 2/s. There are
differences in hydraulic conductivity for different rock types. Average hydraulic
conductivity (test length 14 m) is 110-7m/s for the fine-grained granite, 110-8m/s for the
Smaiand- granite and- 110-9m/s for the Aspo diorite.
Of special importance with respect to grouting is the geology of the major fracture zone
NE-1. The zone was investigated in the pre-investigations and tests revealed a high
transmissivity in the order of 0.8 - 810-4 m 2/s. The zone was further investigated from
the tunnel and from the surface and these supplementary tests showed that the zone was
highly water- bearing (410-4 m 2/s), trending N60E and dipping 70 to the north. The
most intensive part of the zone is approximately 5 m wide, highly fractured or crushed
and including a 1 m section with high clay-alteration. The gouge material includes
fragments of all sizes from cm-scale to < 125 J.lm. Fragments are sharp angled and
consist of more or less tectonised granite and mylonite. The intensive part of the zone
with open, centimetre-wide fractures and cavities is surrounded with minor inclusions of
greenstone and mylonite where the most intensive part of the zone is located in fine-
grained granite.
31
While grouting could destroy the possibility to reach stage goal 1 - verify site
investigations - and also destroy future opportunities for experimental work - test of
models groundwater flow and solute transport - during the operational stage, the
seepage requirements were quite loose. The general idea was really to avoid grouting if
really not necessary. To minimise environmental impacts, the Water Court permitted
SKB to divert 50 1/s (3000 1/min or around 80 1/min, 100 tunnel-m). However quite late
in the site investigations it was shown that the NNW-swarms in the future laboratory
area were quite conductive and would require grouting and it was decided to limit the
spread of the grout to 5 - 10 m from the tunnel periphery not to damage the ground water
chemistry nor the ambient hydro geological properties of the rock.
The hydrogeological groundwater flow model assumed grouting in the following

pragmatic way: Where there are fracture zones that would leak more than 180 1/min
without grouting, it was assumed these were to be grouted to a maximum seepage of
180 1/min.
Overview
The original tender documents followed the established Swedish practice at that time
and the tender documents were quite similar to the approach at the Bolmen tunnel.
Based on probe holes or inflow through blast-holes or the tunnel front, pre-grouting is
performed when considered necessary. The requirements were not translated to definite
grouting criteria depending on inflow in probing holes or in grouting holes. Typically a
grouting fan of 10- 25 grouting boreholes is drilled, tested by water-loss measurements
and grouted. The grouting starts first with a high water-cement-ratio (with a few %
bentonite added) and later reducing the w/c- ratio to obtain a thicker grout. The tender
document also required the contractor to develop and adapt the grouting work to gained
experiences.
It was known that the ramp would pass a major fracture zone - the NE-1 zone at a depth
of - 180 m and a special project was set up to integrate testing and construction
activities in the work. The project is documented in SKB Progress Reports
25-92-18A-D with a summary description in Gustafson et al (1994). A pilot test was
conducted in the fracture zone EW -7 with a subsequent test in the NE-3 fracture zone,
(Stille et al 1993). To limit grout spread a grouting rule was decided by the client SKB.
The maximum grout volume per grout hole was restricted to 600 litres in good rock
(RMR > 60) and to 1500 litres in poor rock (RMR < 60).
StabiloGrout (Bolmenbruk) was added as a grouting material in addition to the cement

groutings. The Bolmenbruk however did not work out very well since the water
pressure is high (> 150 m) and the grout has quite low shear strength for several days.
The grout extruded from the grouting holes when packers were removed some 6- 10
hours after grouting. After many unsuccessful attempts the contractor Siab finally
32
decided to try a mixture of cement and I5 % salt (CaClz) and this proved to be a
satisfactory remedy not accounting for longevity. The chemical polyurethane grout
T ACSS was used with little success and this might be contributed to the fact that
TACSS do not expand at high water pressures, (Andersson I998).
Grouting performed
Table 4-2-I and Table 4-2-2 provide an overview of grouted volumes for Stretch 0/000
to 11340 and for Stretch 1/340 to section 2/565 respectively. In the former Stretch I03
groutings were performed. 52 of these were in fracture zones NE-3 or in fracture zone
NE-1. 42 % of all groutings were re-groutings and these were mostly located to the
fracture zones. The average grout consumption was 2700 1/grouting fan. In the latter
Stretch 42 pre-groutings were performed. I4 % of the groutings were related to probe
holes. The average consumption per grouting fan was 5700 I.
Grouting materials
As a preparation for the passage of NE-I several grout material were tested, c.f.
Table 4-2-3.
Figure 4-2-I a) and b) show the increase in yield strength for different mixes of
additives. It was observed that use of grouting cement (IC) with w/c of 2 and 3 were
highly unstable and as much bleed as 50 - 70 % were recorded. The use of Bolmenbruk
offsets this effect. However, at a water pressure of around 1.5 MPa, the Bolmenbruk did
not work properly as the grout extruded from the grout holes when packers were
removed. Cement (w/c I.O and 0.8) was used with CaCiz as additive. The Figure 4-2-2
reflects the concern to find a suitable grouting material when the NE-I was excavated
through. The passage of this major fracture zone of a few metres took some two months
to complete.
Table 4-2-1. Grouting performed in Stretch 0/000 - 11340 (Stille et al1993).
Fracture zone Fracture zone Remaining

Issue TOTAL
NE-3 NE-1 tunnel
Grouted volume (I) 49000 86000 I32 000 267 000
Drilled hole length (m) 2 820 6 I79 8 3IO I7 309
Grouted length
3I 23 560 6I4(43%)
of tunnel (m)
Grout volume per
I 580 3 780 240 I9I
meter of tunnel (Vm)
Drilled length per
meter of grouted 9I 270 IS 28
tunnel (m)
33
Table 4-2-2. Grouting performed in Stretch 11340-2/565 (Stille & Janson 1994).
Grouting Probing
Issue TOTAL
Fans holes
Grouted volume (I) 150 500 60500 211 000
Drilled hole length (m) 3 470 1180 4 650
Grouted length
220 520 600 (49 %)
of tunnel (m)
Grout volume per meter of 685
115 285
grouted tunnel (1/m)
Drilled length per meter of grouted
16 2 6
tunnel (m)
Table 4-2-3. Grout materials tested in laboratory for use at the Aspo HRL.
Grout Blaine Dtoo

(m2/kg) (!Jm)
Cement
Degerhamn Grouting IC 600 64
Skovde SH 480 128
Slite Std P 370 128
Mikrodur P (MD) 1200 16
Prompt (PR) 550 12
Additives and admixtures
Bentonite (Brebent)
Napthalene-based plasticizers (HP, Rescon)
Polymerizing special silicate (Stabilodur F1)
Calcium chloride (CaCb)
100
100 r Hogh OI!!OUnl of
silicalt !6%)
10 '
ll 0.1
~
i 0.01 :; 0.01 ;
~.........___.
;. e:s:::s:~...-
t i"'t [hours I hme [hours)
a) b)
Figure 4-2-1. Increase in yield strength as a function of time a) cement with changing
% of CaC/2 b) Bolmenbruk with changing % of silicates (Gustafson et a/, 1994 ).
34
VJO VJ20 VHO
6417 I
50)7 I
51 15 I
. llo i ,..,I.IC
L Jtres
JIOO . Ac:c:
3eOO
J.COO en.m
.uoo
lOOO
2800
26o0
2400
2200
2000
1100
1100
1400 , TACSS
uoo
1000 ~~ Horoen lno
oo
100 ~ lt., loliJI
400
zoo
0
IS I& t7 ..!J ~ 0 10 11 1J 7l 74 7S 76 11 11 7t ell 11 12 tJ 14 IS .. a1 11 19 JO 91 12 U IIKord No.
I ~~:0 c I V292 I v2~ vm I I Ivfa

vm VJOt
c:/dgn/ra _1Mel . dqn f'eb . 4 , 1993 08:49:20
Figure 4-2-2. Overview of use of grouting materials in the NE-1 fracture zone
(Gustafson et al1996).
Blasting
The length of the rounds was shortened in poor rock. Also smooth blasting was used at
poor rock or where grouting was performed. The standard blasting procedure was to use
Gurit 17 for both periphery and helper holes and down to Dynamex 25 mm in the floor.
The seepage per section is outlined in the Table 4-2-4 and estimated penetration in
Table 4-2-5. It is clearly evidenced that problems really occurred to seal the NE-1
fracture zone (Stretch 11290- 11306) in spite of comprehensive efforts.
In hindsight there were many problems that should have been considered more
thoroughly in the design and engineering work prior to construction. However the
experience created spin-offs like a structured approach to the constructability analysis,
an R&D programme on grouting and also the proposal to construct a prototype
repository at Aspo HRL to learn all practical matters.
35
Table 4-2-4. Water inflow to the tunnel as measured by weirs. (Stille et al1993), (Stille
& Janson 1994), (Gustafson et al1996).
Tunnel Measured Measured inflow % Inflow in roof and

stretch inflow walls and its character
(Vs) (1/min, 100 tunnel-m)
0/000 - 0/672 1.2 10
0/672 - 1/030 7.8 138
1/030 - 1/233 3.0 89
1/233 - 1/372 7.1 426 37 % (mostly flow rather
than patch of moisture or
sporadic drips)
1/372 - 1/584 1.2 73 85%
11584- 11745 0.3 10

11745 - 1/883 0.5 23
1/883 - 2/028 0.6 25
2/028 - 2/178 1.6 66
2/178 - 2/357 1.1 36
2/357 - 2/496 0.1 3
Table 4-2-5. Estimated penetration of grout from the tunnel periphery (Stille et
al. 1993), (Stille & Janson 1994) and (Gustafson et al1996).
Zone Penetration Penetration

(m) (m)
(Stille et a11993) (Gustafson et al 1996)
EW-7 6-17
NE-3 2-13
NE-1 3-13
NE-1
roof > 2.5
left wall >12.5
right wall >12.5
floor >3.5
Distance is less than
35 - 50 m as the grout
did not reach surrounding
boreholes
Table 4-2-6 shows the correlation of predicted inflow to the tunnel compared to
measured inflow. While SKB decided to excavate parts of the facility with a TBM,
layout changes were made and it was not possible to follow-up all predictions to full
depth.
36
The Figure 4-2-3 shows the inflow to the tunnel over time. The added inflow for the
deeper part was quite low, as the tunnel does not cross any major fracture zones. Also it
is shown in the figure that the inflow decrease with time.
Table 4-2-6. Water inflow to the tunnel stretch 01700- 21875 m when the tunnel face
was at 2/875. Skin factor 10 (Rhen et al1997).
Tunnel stretch Prediction Outcome Depth for sample

(1/min) (1/min) (m)
0/700- 1/475 840 1210 100-200
0/700 - 2/265 1470 1660 100- 300
0/700-2/875 1860 1722 100-400
2 3 4 5
0.04
0.03
0.01
0.00
M00 ~~~~~~~~~~~~~~~~~~+1
: 3100
~ 2700
c
Cii
'fi 2300
a;
~ ~rf'l~il'l: i:2!i*;:~: :c~

1900
~ 1500 ~''''"--'-'""
c
;:,
t-
1100
700
...9 ... ....
0 9 0
....
0 0 0 9 0 0 0 .... 0 .... 0 0
m N.... 9 m
0 0
9(") m
en N m N (") m a, N M 9 .;, N
9 9 9 .... q 0 .... 0 9 q .... ....
CO (") CO
9 0 9 9 0 9
.... N
I
N NI
en c;; a; en Nen en en en en en 0> ~ en

(") M
(")M ~ ~ ..f.
0> en
11)
cn
.;, 11)
0> 0>
&},
0>
Figure 4-2-3. Flow into the tunnel section 0-3/600. (Rhen et al1997).
-l
37
4.3 The Hallandsasen Railway Tunnel
The information on the Hallandsasen Railway Tunnel is compiled from several

documents on CDs to the Swedish government by the Swedish National Railway
Administration (Banverket) and by special review groups designated by the
government. The information has also been discussed at a site visit when the site
manager Kenneth Rosell, Banverket, was interviewed.
The client Banverket constructs tunnels through the Hallandsas to modernize the
railway-system Gothenburg-Helsingborg-Malmo. Two single-track tunnels each at a
length of 8600 m were to be constructed through the Hallandsas - one of the major
Scandinavian horsts. The construction work started year 1992. The contractor at that
time selected an open gripper hardrock TBM but had later to switch to traditional
excavation by drill and blast. In year 1995, the contractor annulled the contract and
Skanska was awarded the continuation. Like the first contractor, Skanska did not
succeed very well to comply with the requirements on maximum inflow and diversion
of ground water as stipulated by the Water Court. Several types of cementitious and
chemical grouting materials were tested to improve the results of grouting operations.
One of the selected grouting materials Rhoca Gil proved to be feasible. However due to
misleading product information the severe environmental and health impacts of the
component acryl amide were not foreseen by the client nor the contractor. The later
environmental scandal where cattle was poisoned and deceased forced the project to a
complete halt when . . . 113 of excavations were carried through, Figure 4-3-1 provides a
general overview of the tunnel and Figure 4-3-2 an overview of the constructed tunnels .
.sv NO
Horsfen Hafla~<tsas
For IOV
t>-~~~IP!!!' ~~5-: PJanerad tunnel
D ~it en1ara bergarter D S .rumentara bl!!rgarter r-::1 :P kam riska ristallina

tlria J)t=h J ra) . {kri ) L-J q~arler
,,,
Kvaritya
. '
avl&~riJlgar
' . I
Figure 4-3-1. Overview showing the tunnel location and geology.

38
Now, to comply with the ruling of the Water Court, Banverket decided to line parts of
the tunnels where major inflow was occurring. The Figure 4-3-3 shows the inflow over
time and advance of construction. Decision to continue the excavation work is still
pending (July 2001) the decision of the government.
Norra p!slaget MeUanpi laget SOdra paslaget
Figure 4-3-2. Schematic view of excavated tunnels (areas in grey).
Inllckage vid det norra plslaget

3000
0
Uppmltt in1lcbae
--- ln1Jc:bae 19801/min X km

c; <?< >~ -1
~
I
-- -- - -- - - -- -- 1$ ~~
-- lnllckap 1980Vmin ~
- 2000 - - -- - -- ---- -
r-- r-- r-- - -- r--
~
I
I"'
0 6
c 1500 L.i.
~6
I ~
[""
~
l~
~ ~ 9= ~
~(j ~ ~ ~ 'P
.o~
.?' -~
--- --- --- --- --- ......

0 -- lP-.. ,., ....... r-r
- ::~
---
Figure 4-3-3. Inflow as a function of advance rate. The 1980 l/min (or 33 lis or around
23 l/ min, 100 tunnel-m (both tunnels) is the maximum permissible inflow.
39
4.3.2 Geology
The Hallandsas is a horst developed as a result of repeated fracture zone re-activation.

The rock mass is dominated by a fine-grained grey-red to red gneiss. Amphibolite
inclusions are abundant and usually concordant to the general sub-horizontal foliation.
Granitoid rocks are seldom prevalent. Diabase dykes are common and they are striking
in WNW as the major fracture zones.
Fracture zones in NW, NNW and NE dominate the brittle tectonics. The NW -zones are
the most dominating zones. Sub - horizontal fracture zones have not been identified, but
could exist, probably concordant with the foliation.
The four types of structures impacting the transmissivity of the bedrock are the diabase
dykes, the amphibolite dykes, the fracture zones and the fracture system surrounded by
the three other types of structural systems.
The fracture pattern mapped in the tunnel is similar to the pattern mapped on outcrops.
The rock quality is classified accordingly to the Q-method, c.f. Table 4-3-1 and
Figure 4-3-4. It is noted that the major part of the excavated tunnel so far is in very poor
rock or worse.
The transmissivity for the rock mass at the North portal is judged to be in the order of
510-5 m 2/s and locally up to 10-3 m 2/s in the central part of the Hallandsas horst. The
transmissivity in perpendicular direction to the horst and in the rock mass in between
the fracture zones are judged to possess the transmissivity 10-4 m 2/s. At the South portal,
it is expected the transmissivity is in the same order as in the North portal, around
510-5 m2/s.
The water table is around 5 m below the surface for the high altitudes and 15 - 25 m
below the surface at the steeping slopes. Locally artesian conditions should prevail. The
tunnel construction has caused a draw down of the water table that is up 100 m below
the un-disturbed water table. Figures 4-3-5 and 4-3-6 respectively show the estimated
distribution of hydraulic conductivity and a groundwater model.
Table 4-3-1. The Q-value and corresponding rock quality.
Q-value Rock Quality

400- 1000 Exceptionally good rock
100-400 Extremely good rock
40- 100 Very good rock
10-40 Good rock
4- 10 Fairly good rock
1-4 Poor rock
0.1- 1 Very poor rock
0.01-0.1 Extremely poor rock
0.001-0.01 Exceptionally poor rock
40
',= ~ ,
.,
~
-
_.
.L ...
0
0.100
U70
!~.
~~
.. . .....
'i.. - ;)_:
~
-~-~- .. .,...
. . . .-:-
.~.
..
- ... - . 'I . ..,_ ,. , ~- ... , "" ~
....
OJMO .-
... .
OA10 ...:.
0#)7
I I.... I I
~
I..... I
orr r
Figure 4-3-4. The distribution of Q-values along the North tunnel. Diagrams on top
shows a simplified view of rock types, fracture zones and fractures.
tl!-'11 !~1 41 <:1. IH't'lo1ikt hl tAI' olnJ li.!.l ). hM~ h lilroi~?'IA

Se4<too 1EIJ &i1:t 19 7fi1
1,E-I:~
. ...... .
1 E-1:14
. . . ..... . ~~... K-
1.F..rt= ....
-
J
::~... ,...n ~....
'!_\l .
"r.
~-..
.... ~..A. ...

~
:1 ~-
~~~
~ . ~
......
...... ~
: .-.
~. "m
~"~
4 '\~~
11,C-OC

~ ~..4 ..
l ,t:.-UJ
'
1,E-O!
1,E-er;
1!U)500 l\t1 1CI) 1~1 4 Xt 191700
Figure 4-3-5. Estimated distribution of hydraulic conductivity along the tunnel stretch.
41
...
tC 8 t ' gy"t;li 'l $- fUVJ
IC.l"< ILMMIH YW 1U I .C1 18 Rtv.O

--
o 10:l~ zocc .!~00 4Q:)O m
Figure 4-3-6. The regional groundwater model.
The application to construct the tunnels was in accordance with the laws in the early
90's. Environmental Impact Statement accordingly to the Act on Environment was not
needed at that time.
The necessary ruling was decision by the water court to divert the inflowing ground
water. The applicant- the Banverket- made investigations that showed:
the inflow would be around 6 1/s, km to 30 1/s, km if only the more conductive
fractures were sealed,
the draw-down should increase the groundwater recharge and create less surface
flow,
the inflow - 3.5 1/s, km - in total 33 1/s from the tunnels would create a limited
water table drawdown - less than 1 m at a distance of 1.5 km from the tunnels,
influence on vegetation and wet areas would be limited,
the high, natural content of iron in the groundwater could precipitate when
oxygenated.
Factors like influence from blasting, grouting etc were not treated in the application.
The water court ruled that the maximum water flow that could be deviated was in total
33 1/s. The court later decided that additionally 15 1/s could be deviated to allow for
influence of ramping at the mid-section of the tunnels to create 4 additional tunnel faces
to speed-up the advance rate.
For the second building contract Banverket required that seepage should be less than
211/min, 100 m for the two tunnel together. Banverket prepared a forecast with
42
7 different grouting classes. It was required that systematic pre-grouting should be

executed and when necessary supplemented by post-grouting. The contractor should
prepare a plan for each of the 7 classes, also explaining choice of grout.
To fulfil the requirements, the grouted zone should possess a hydraulic conductivity less
than 11 o-9 m/s.
These descriptions outline the procedures, as they developed during the course of the
project:
Probing
Probe holes and grout holes (diameter 64 mm) should deviate at maximum 5 % at the
end points of the hole. After grouting, 3 probe holes will be drilled at the same length as
the grouting fan. If the accumulated probe hole inflows exceed 1.6-1/min grouting
should be executed, also if blasting holes are flowing.
In the Skanska contract three control holes were to be drilled 2 m shorter than the
grouting fan. If the accumulated flow exceeds 0.12 1/min, m or if flow from one of the
holes exceeds 0.007 1/rnin, m one additional round of grouting were to be executed.
Four probe holes were drilled at the same length as the planned grouting fan.
Water-loss measurements
No water-loss measurements were made but inflow to the holes were recorded.
Grouting holes
The drilling was made in the following way (first contractor): 20 m long holes were
drilled from the periphery. Endpoints should be around 5 m from the periphery. The
number of holes was set so distance between end points were to be 2 m at a distance of
15 m. Also 4 - 10 grouting holes were drilled in the tunnel face. Overlap between
grouting fans should be at least 5 m.
In the second contract, 18 holes, 14 m long inclined at 10 were to be drilled.
Grouting
In the first contract, the grouting schemes constantly were in a transient change as
grouting was more difficult than anticipated, especially for rock being moderately
altered, but heavily fractured.
43
In principle grouting changed as follows :

1. Pre-grouting in 12 - 20 holes, each 20 m long. Grouting material was accelerated
cement grout with low w/c-ratio.
2. Grouting fans with 16 - 20 holes, 14 m long. Mix of cement and chemical grout
(Glyoxal).
3. Grouting fans with 20- 25 holes, length 14 m, injected with cement grout and high
w/c-ratio. The cement type used was usually the Cementa Injekteringscement.
Grouting was to be made at a pressure at least 1.0 MPa higher than the groundwater
pressure and continue until one of three conditions were met, either up to 1000 kg
cement per hole, or maximum 1 hour per ~ole or flow < 3 1/min at maximum pressure.
Tests were made with very long fans (30 m) with secondary grouting fans in between
the primary holes as grouting problems continued; grouting was also made with
standpipes. Like in dam grouting, holes were grouted level-by-level. While problems
continued, tests were made to switch grouting materials away from the Cementa
Ultrafin 16 !Jm, w/c = 0.8 cement, 4 % super-plasticizer, c.f. next section. The grouting
work was very difficult and advance rate for the tunnel was only 3.5 - 10 rnlw. Tests
were quite successful using Glyoxal in combination with cement. These grouting fans
were drilled with 42 holes, 14 m long plus 4 holes in the tunnel face.
As mentioned earlier, Skanska was awarded the second contract. The specifications
were changed as follows:
1. Four probe holes were drilled to the length of the grouting fan
2. Flow from the probe holes were measured and recorded
3. Grouting fan was drilled. The principal design was 36 holes along the periphery so
that end points were 5 m from the intrados resulting in a 2 m separation in roof and
walls and 1 m for the holes in the floor. Overlap between fans should be at least the
length of the blasted round or 3 m
4. Grouting overpressure should be at least 1.0 MPa but less than 5.0 MPa relative the
ambient ground water head
5. If grouting flow was less than 3 1/min or the grout consumption was > 50 kg/m of
borehole, grouting should be terminated by plugging using a low w/c-ratio and
accelerator.
Banverket asked the contractor to make a plan accordingly to 7 different grouting

classes and Skanska proposed accordingly to Table 4-3-2 (See also section on grouting
material).
~-------~~
44
Table 4-3-2. Grouting schemes for 7 rock classes.
Rock Description
Class
1 36 holes, 17.5 m. Grouting with Finbruk to final grouting pressure,
minimum 5.0 MPa or 50 k /borehole m
2 2 grouting fans, each at 18 holes, 13.2 m long holes. Grouting with Finbruk
changing into Styvt bruk after 40 kg/borehole m grout take. Stop as for
Class 1
3 See Class 2
4
5 and grouting with Tillviixtbruk.
6
7 with chemical rout
The maximum water head encountered in the grouting operation is 12 bars (120 m) .
Practical problems occurred to place the grouting packers due to the high pressures.
Grouting materials
The first contractor required the client to pre-qualify the cement grout materials. Three
types of grout were to be tested:
1. Grout with as good penetration as possible; low-viscous grout for sealing of fine
fractures
2. A viscous grout for not so fine fractures
3. An accelerated grout for application at high grout flow and water flow .
Vattenfall Utveckling AB tested a suite of grouts to study filtration, penetration in slots

and in sand, bleed, volume, yield, hardening, strength and permeability.
Four different mixes were tested in field-tests on site:

Cementa Ultrafin 16 w/c = 0.8, 4 % super-plasticizer V33
Spinor A16 w/c = 0.8, 1 %super-plasticizer Rescon
Rheocem 650 w/c = 0.6, 3% super-plasticizer Rheobuild 1000
Stdibrukens Injekteringscement,w/c =0.6.
The contractor initially chose to use the Cementa Ultrafin 16 cement.
Chemical grouting was applied at a later stage by using Glyoxal. Glyoxal is the
denomination for diformaldehyde, being used in a water solution. Glyoxal grout is 50%
natrium- potassium silicate, 8 % of glyoxal, 8 % acetic acid and the rest water. The
glyoxal is the curing agent.
4S
For the second building contract Banverket described four types of grouts to be used:
Finbruk Low-viscous cement grout with low yield value 'to= 1 - SPa and particle
size d9s < 16 !Jm. Bleed within 2 hours maximum S %
Normalbruk Yield 'to = S - 10 Pa. Particle size d9s < 64 !Jm. Bleed within 2 hours
maximumS%
Styvt bruk Yield 'to = 10 - 1S Pa. Particle size d9s < 64 !Jm. Bleed within 2 hours
maximumS%
Tillviixtbruk Yield initially 't0 = 1 - S Pa. Particle size d95 = < 16 !Jm. Accelerator is
added so 'to is 1S - 20 Pa after 1S - 20 minutes. Bleed within 2 hours
maximumS%
Kembruk Silicate-based gel solutions and polyurethane foams in special cases.
Skanska selected the grouting materials accordingly to Table 4-3-3 :
Grouting with Finbruk did not work out well and several changes to the scheme was
made, but with poor results until Glyoxal was used. However, in spite of excellent
sealing results, Glyoxal had to be abandoned due to the question of longevity. Other
chemical grouts were tested, RHOCA Gil, Rascoflex och Meyco MP 307 and the
decision was to continue with RHOCA Gil with excellent sealing results. This decision
later caused a complete halt of the project, as the RHOCA Gil is extremely hazardous
with unacceptable environmental consequences. Polyurethane foam (T ACSS) was used
to seal shallow seepage at the periphery.
The amount of cement grout is around 2000 kg of cement per tunnel metre (25 - 50 kg
cement/borehole m). The amount of chemical grout used is shown in Table 4-3-4.
Field tests were made March - April 1997 at the central access tunnel for the
0/767- 0/850 m sections. The seepage without grouting was calculated to 1300 1/min.
The total seepage after grouting and excavation was 100 1/min; the overall flow
reduction thus was 92 %. Based on flow in probe holes and control holes after grouting,
the flow reduction was 73 - 100 % (median value 89 %) if the effects of one re-grouting
were accounted for.
Table 4-3-3. Grout material as proposed by Skanska.
Grout Description
Finbruk Cementa Ultrafin, w/c =0.8, 4 % Cementa super-plasticizer V66
Styvt bruk Cementa Injekteringscement, w/c = 0.6
Normalbruk Cementa Injekteringscement, w/c =0.6
Tillvaxtbruk Cementa Ultrafin 16, w/c = 0.8 and 2% NaOH
Kembruk Ascania silicate, N2. Gecedral as curing agent OR
"Bolmenbruk" (Accelerated grout with Injekteringscement,
bentonite and silicates.
46
Table 4-3-4. Usage of chemical grouting material.
Grout Main Amount Time of usage

components (metric tonnes) (year, month,
day)
Glyoxal Acetic acid, glyoxal, 2693 931211-950214
silicates
Bevedol!Bevedan Iso-cyanates 4 950828- 951003
Gecedral Silicates and Na- 13 970320-970417
aluminates
TACSS Pre-pol ymerized lSO- 6 970306 - 970316
cyanates
Meyco H ydroxiemetalacrylate 80 970611 - 970624
Rascoflex Metaacrylic amide 99 970606- 970611
RHOCAGil Acrylic ami des and 1408 970324 - 970930
silicates
The conclusions on sealing efficiency, based on 16 grouting fans were:

Cementa Ultrafin without Groutaid (silica fume to mitigate separation water-
cement) had a sealing efficiency of 70 %
ditto with Groutaid was 90 %
Rheocem 650: 98 % in average. No differences when using Groutaid could be
decided.
Estimated flow reductions for different choices of grout materials are presented in
Table 4-3-5.
With respect to cement types, the use of microcement has some practical limitations. As
the fine part (< 1 J.lm) is substantial, the reactivity is high and the cement form early
aggregates. The cement is also sensitive for temperature and age of the mix that
necessitates strict working procedures at the site. The use of Cementa 30 J.lm with
lowered parts of < 1 J.lm has shown good results at the Sodra Hinken project. The
Cementa 30 J..lffi has also been used at post-grouting at the Hallandsas-project with good
results and the crew think this cement is superior to the Cementa 16 J.lm.
Probe holes after grouting
Probe holes and grout holes should deviate at maximum 5 % at the end points of the
hole. After grouting, 3 probe holes will be drilled at the same length as the grouting fan.
If the accumulated probe hole inflows exceed 1.6 1/min grouting should be executed,
also if blasting holes are flowing .
47
Table 4-3-5. Estimated flo w reductions. Sections 190 + 590- 191 + 800.
Grout Number of Mean flow

grouting fans reduction%
(SP = super-plasticizer) with useful (lognormal
data distribution)
Cement
Ultrafin, high w/c, 2 % SP 60 73
Ditto + Groutaid 17 81
Ultrafin, low w/c, 2 % SP 8 48
Injekteringscement, high w/c, 2% SP 8 30
Bolmenbruk 5 21
Rheocem 650, high w/c, 2 % SP 5 80
Kembruk
RHOCAGil 49 98
~
Glyoxal 17 95
Mix of cement and chemical grout
Ultrafin 16, low w/c, 2 % SP +Glyoxal 7 93
Ultrafin 16, low w/c, 2% SP + Gecedral 5 15
Ultrafin 16, high w/c, 2 % SP + Gecedral 5 69
In the Skanska contract three control holes were to be drilled 2 m shorter than the
grouting fan. If the accumulated flow exceeds 0.12 1/min, m or if flow from one of the
holes exceeds 0.007 1/min, m, one additional round of grouting were to be executed.
Blasting
For the Skanska contract, length of the round should be set so there always is a 3 m
grouted zone ahead of the tunnel face.
In general the maximum blasting damage zone strived for was 0.3 m in the walls and
roof and 1.2 m in the floor. Typically a round was charged with Gurit 17 mm in the
periphery and Dynamex 29 mm in the floor. Quite a few experts think that blasting do
not destroy the grouted zone, which is quite a surprising opinion.
Grouting in the South tunnels were easier than in the North tunnels and the frequency of
re-grouting was only 14 - 20 % due to better rock conditions. The flow reductions are
shown in the Table 4-3-5 . The Table 4-3-6 shows the thickness of grouted zones.
90 % of grouting is pre-grouting. Post-grouting was made 1998 - 1999 more like tests
than a systematic post-grouting operation.
1-
48
Table 4-3-6. Thickness of zones grouted with Rhoca-Gil.
Type of Number Total Average Minimum Maximum Standard-

grouted of number thickness thickness thickness deviation
area grouting of of of grouted of grouted
fans boreholes grouted zone zone
zone (m) (m) (m)
(#) (#) (m)
In areas
close to
4 12 12 4 20 6
Rhoca-Gil
groutings
Post-
grouting
6 36 9 3 20 5
with
Rhoca-Gil
Pre- 26
grouting max drill
8 48 9 4 4
with depth
Rhoca-Gil 26m
4.3.6 Miscellaneous studies
Banverket also conducted tests with a new type of concrete technology marketed by
Senad Teknikbetong AB based on that air bubbles are mixed into the cement as carrier
of particles. Tensides are also added into the cement. The cement foam will be
homogeneous with respect to cement particles and airbubbles and its distribution.
The original idea was to execute a three-stage project, but only the first stage was
carried through in spite of results were deemed to be successful. The first stage was
post-grouting in the section 197/780- 197/810. The seepage decreased by 50% in spite
of no grouting of the tunnel floor. The full report is found at www .senad.se. Tests are
also in progress at the Sodra Lanken project.
4.4 The Lundby Road Tunnel
The Lundby tunnel in central Gothenburg is one of the longest and most tight road
tunnels ever constructed in Sweden. A short overview is in Table 4-4-1 .
An overview of grouting work and experience is the paper by Bergab (1994), Eriksson
& Palmqvist ( 1997) and discussions during a site visit. Some results are extracted here.
49
Table 4-4-1. The Lundby twin-tunnel - short facts.
Issue Fact
GENERAL
Start of construction Aug 1994

Start of operation Jan 27, 1998
Tunnel length (m) 2060
Depth below surface (m) 5mto40m
Tunnel span (m) Each tunnel span is -10m and a
- 10 m pillar is in between
Tunnel area (m2 ) North tunnel 86 m 2 , South tunnel
92m2
ROCK CONSTRUCTION
Excavated rock (mJ) 405 000

Rock bolts 34000
Reinforced shotcrete 40 - 130 mm (m2 ) 94 500
Shotcrete arches (m2) 600
Grouting cement (tonnes) 2 343 (- 570 kg/m tunnel)
Chemical grout (TACSS foam) (l) 52 735
Rhoca Gil (l) 650
COSTS
Total cost 680MSEK

Cost for grouting (MSEK) Total: 60 MSEK
Pre-grouting 25 MSEK
Additional pre-grouting 1 MSEK
Post-grouting 27 MSEK
Water-drip chasing 7 MSEK
4.4.2 Geology
The rock is a gneiss-granite with inclusions of massive greenstones, pegmatites and

aplites. The rock is slightly foliated N-S dipping W (45 - 75). (The main direction of
the tunnel is NNE-NE-E.) Fractures are pre-dominant! y vertical and strike is
N65W- N70E. Fractures E-W are open or infilled with calcites.
Zones along the foliation are ductile nappes where mylonite occasionally exists with
clay alteration. The water flow in the zones can be substantial if clay alteration is sparse.
Sub-vertical fracture zones are mostly oriented N 70W and E - W. These zones are
either open or completely or partly filled with calcites. Also clay infillings are to be
50
found. In addition to sub-vertical zones there are sub-horizontal zones including narrow
fractures with limited extent.
To support engineering, 450 m of core drilling were made. The three holes, each 150 m
long, were drilled at a dip of 30 and deviated to be drilled along the tunnel line.
Unfortunately, no measurements were made to determine the distribution of
transmissi vi ties.
The permissible drawdowns that do not cause damage have been calculated. Based on
these calculations maximum inflow was calculated, and the selected grouting scheme
decided, Table 4-4-2 It is evident that the requirements are very high.
Descriptions of the grouting schemes are outlined in Table 4-4-3 . The three schemes are
basically three drilling patterns.
The straightness of grouting holes was tested for 5 - 20 % of the grouting holes. A tube
was pushed into the borehole to fit the diameter to the diameter of the testing
equipment. The maximum permissible bend was set to 0.8 m 113 m, (Udel &
Thorild 1995).
Blasting was made accordingly to classification of rock quality and seepage

requirements. In general cautious blasting- or extremely cautious blasting- was carried
out. Typical charging patterns, Table 4-4-4, show that very cautious blasting has been
used.
4.4.5 Overall result of grouting operations.
The overall tightness achieved is quite impressive. Eriksson & Palmqvist ( 1997) reports
successful sealing, Table 4-4-5 One interesting comment in Eriksson & Palmqvist
(1997), is that re-analysis of requirements showed that 0.8 1/min, 100 tunnel-m was
sufficient to mitigate environmental impact, where the inflow was higher than the
requirement 0.5 1/min, 100 tunnel-m, c.f. Table 4-4-5 .
The section 2/340 - 2/450 where the original requirements are not met, is in a
complicated geology. The report by Bergab (1994) shows that this particular section is
of very poor rock quality and that a sub-vertical fracture zone with intensively crushed
rock and gravel-clay weathered rock is likely to dip to East. The sub-horizontal
structures and the sub-vertical were deemed to very transmissive.
51
The successful results are contributed to:

the geological forecasts were accurate and thereby facilitating a smooth interaction
with the contractor
strong client supervision and control of work associated with the grouting work
careful cleaning of tunnel floor to detect water inflow to the tunnel floor before post-
grouting
creation of an "inner curtain" at the tunnel intrados by use of T ACSS to create a
prop for later post-grouting. This technique was used at the difficult sections at
around 2/400, c.f. Table 4-4-5.
At the site visit, inflow to the tunnel was checked. The south tube inflow was 23.5 1/min
and the north 12.51/min a total of 361/min. This equals in average
36/41 = 0.91/min, 100 tunnel-m.
Table 4-4-2. Maximum inflow at different tunnels section to minimize damage.
SECTION GROUTING SCHEME MAXIMUM

PERMISSIBLE
INFLOW
(1/min, lOOm tunnel)

0/600 - 1/190 3 2.5
1/190 - 1/780 2 1
1/780 - 2/040 2 2
2/040 - 2/660 1 0.5
52
Table 4-4-3. Description of grouting schemes.
SCHEME DESCRIPTION
1 - for extremely low Probing
inflow Probe holes are c/c 3m at 5m above the roof. Holes are drilled every
second round (4 m) with 4 m overlap. Water-loss measurements are
performed in the probe holes
Water - loss measurements

Measurement pressure is 0.5 MPa over the groundwater pressure and the
time used is 5 minutes after stationary conditions are met. At > 10 1/min, m,
MPa the grouting is made with TACSS. At the range 1-10 1/min, m, MPa
cement is used. At lower values chemical grouting is made.
Grouting holes
The end points of grouting holes are separated by 1 m at maximum. The
holes should be graded in the roof so end points are at least > 4 m from the
periphery so rock bolts do not penetrate the grouted zone. The same
applies for the grouting holes in the walls. The length of the grouting fan is
selected so two 4-m rounds can be blasted. First every second hole is
drilled and water loss measurements are made. When there are leakages in
the tunnel face, additional holes are added.
Holes are to be straight. Maximum deviation at starting point is 0.1 m and

0.5m at the endpoint. Deviation at starting point should be less than 2.
After grouting every second hole is drilled (> 2 h waiting after grouting) and
measured and grouted.

At least 4, 10 m long probe holes. Water-losses decide further grouting. Dry
holes are filled with cement w/c < 0.35.
Grouting
Holes with the biggest water-losses are injected first. Holes that are
interconnected should be grouted first. Grouting is made by cement and
water with additives to compensate for shrinkage. 2- 5% bentonite are to
be added. Stop-pressure is normally 2 MPa, but 0.5 MPa is made where the
overburden is low. Grouting is made by w/c of 3 for 20 minutes. If stop-
pressure is not reached, or injection pressure is lacking after 20 min, the
w/c is changes to 2. If this mix does not increase pressures within 30
minutes, the w/c 1 is used. After grouting, holes are sealed with cement w/c
< 0.35.
Grouting material
Grouting cement ~specific area > 600 m /kg) is usually used, but micro
2
cement (> 1000 m /kg) is used occasionally.

2 Grouting holes
As for Scheme 1. but every second hole in the walls and the roof
Occasionally
3 As for Scheme 1, only every second hole is drilled. Blasting rounds are 5 m
long
53
Table 4-4-4. Typical records of charging of boreholes in the Lundby tunnel (Drill hole
diameter 48 mm).
CLASSIFICATION PERIPHERY HELPERS FLOOR

HOLES
VTS2 B3 Detonex 80 80 g/m Emu lite 100 25 mm N orex 90 29 mm
VTS2 B2 Detonex 80 80 g/m or Emulite 100 25 mm Norex 90 25 mm or
Gurit 17 mm Dvnamex M 25 mm
VTS2 B1 Detonex 80 Emulite 100 16 mm Emulite 100 30 mm
or Gurit 17 mm
VTS1 B1 Detonex 40 12 mm Emulite 100 16 mm Emulite 100 30 mm
or Gurit 22 mm or Gurit 22 mm
Table 4-4-5. Measured inflow in the North tunnel tube Jan/Febr 1997. (Eriksson &
Palmqvist 2000)
SECTION REQUIREMENT MEASURED INFLOW

1/min, 100 tunnel-m 1/min, 100 tunnel-m
0/600-1/190 2.5 1.1
1/190 - 1/780 1 0.9
1/780 - 2/040 2 1.5
2/040 - 2/660 0.5 0.85
2/070 - 2/190 0.8
2/190 - 2/340 0.8
2/340 - 2/450 1.3
2/450 - 2/575 0.5
4.5 Miscellaneous projects
The Noteby AS thinks that it is difficult to grout to a lower hydraulic conductivity than
2.510-9 m/s, based on Norwegian experience in the Oslo area. The statement is found in
the Hallandsas documentation.
The Electrowatt Engineering & Jager mbh thinks it is very difficult to achieve less
hydraulic conductivity than 11 o-7 m/s using cement grout. The statement is a part of the
Hallandsas documentation. If the lowest possible hydraulic conductivity is 11o-7 m/s
the sealing efficiency is in the order of 60 - 95 %. The results from Hallandsasen using
cement grout are in this range.
In the following information of two recent projects are extended, namely the Arlanda
Railway Project and the Sodra Lanken Project.
54
4.5.1 Arlanda Railway Project
The Arlanda Railway Project connecting the City of Stockholm with the Arlanda airport
via a dedicated railway is the first really Build Operate and Transfer (BOT) project in
Sweden. The rock construction work includes excavation of 800 000 m 3 of rock in
tunnels and terminals. Hassler & Forhaug (1997) shortly describes the grouting
operations in a paper. The maximum permissible seepage was 5 1/min, 100 m. Standard
procedures were used. Grout material was microcement/ultrafine and w/c-ratio should
be less than 0.8 due to reasons of longevity. Plasticizers were permissible to use, but not
bentonite. Maximum grouting pressure was 0.15 - 4 MPa depending on the surrounding
facilities.
One interesting aspect is that the contractor' s production manager on his own
responsibility changed the grouting pressure to 4 MPa from 2 MPa in one particular
working site as defined in the contract specification without any notification or the
client's approval. Such working procedures will not do in repository construction due to
many reasons not the least that construction will occur within a nuclear facility
construction framework.
4.5.2 The Sodra Lanken Road System
The Sodra Lanken Road System is a part of the Stockholm Road Links to decrease
number of vehicles needing to pass through downtown Stockholm, Figure 4-5-1 .
The maximum permissible seepage is 1-4 1/min, 100 m depending on the environment.
Like in the Lundby tunnel there are severe problems with the measuring weirs, to get
them in place as stipulated in the contract and also to get good figures on the seepage as
there is ongoing construction, leaking pipes, valves etc. Even as late as in May 2001 no
good readings on total seepage to the Sodra Lanken road was recorded and it is thus
very difficult to control that seepage is less than the required level.
Like in the Lundby tunnel there are a set of grouting schemes depending on the rock
conditions (water-loss measurements) and the requirements on maximum seepage.
Pre-grouting is continuous. Figure 4-5-2 depicts a typical drilling pattern. Drilling of

holes CD is first made; if one or several CD-holes is groutable, also holes Q) are drilled.
Control holes K1 decide need for supplementary grout holes; if all CD-holes are tight,
control holes K1 and every 3rd Q)-hole is drilled; if water-loss measurements record
> 0.15 1/min, MPa in control holes in the floor also the remaining Q) holes are drilled.
Control holes K2 are drilled to check grouting in grouting round # 2. Drilling is quite
strict, as the end-points should deviate less than 40 mm/m of borehole from the
theoretical end-point (i.e. 0.8 for a 20 m long hole).
After drilling, the holes are cleaned by using at least a pressure > 15 MPa and a flow of
>20 1/min. Water-loss measurements are at 0.5 MPa over the ambient ground water
head for at least 2 minutes. Re-grouting is made if water-losses in the control holes are
more than 0.15 1/min, m, MPa. Grout material is mainly Microcement or
Injekteringscement with the latter cement as the first choice. Water-cement ratio is 2 or
55
1 depending whether water-loss measurement is less than 1 or more than 1 1/min, m,

MPa and amount of plasticizers 1-2 %. Additives are also used to achieve a stable grout
if needed. Blasting is similar to the procedures at the Lundbytunnel and the damage
zone should be less than 0.6 m in the floor. The inflow (July 2001) is in the range of
1 1/min, 100 m for SLO 1 part and 1 - 1.5 1/min, 100 m for the SL02 part and this is prior
to any systematic post-grouting.
The Sodra Lanken Project is (June 2001) also preparing tests with the Senad
Teknikbetong AB procedures. c.f. Section 4-3-6.
Figure 4-5-1. The Sodra Liinken connects Essinge Highway in the West with Varmdo
High- Way in the East. 4.5 km of the 6 km road is in rock tunnels. 98 % of the
excavations were completed in May 2001 . The link will open in 2003.
56
TAntiSKLASS 1A (l}f 2A
fnlJn;J ~ diiSS M nl 2A
tiBIERNiSH&- tiR1AL SKARrf..Atal
&Tt!llie ltr !fTJJi1j-fll7flii lerrjh d s/Fid
!IlMA , .
Salt ffA1
TATN115SKLASS 1A Q(H 2A
ffwfiTJ tn}l class t4 i1l1 2A
INIKTERillSHAl - tm1Al. SKARt1.A~
/krt!lrie ltr IJWiir}-fU1Tid lert;lh d shP/d
L.AIIIJIIVl.
ltnj/tllltl,.,
MAUCO
5rMf.W
Figure 4-5-2. Drilling of grouting holes- the Sodra Liinken project (Viigverket 1997).
57
4.6 Discussion of the cases
The cases described in sections 4.1 - 4.5 span over a range of time periods, geological
conditions, requirements and grouting technologies, c.f. Table 4-6-1 for an overview
What are the present expert opinions on grouting methodology? Rosell, 2000 discusses
this matter and his comments are here extended.
4.6.1 What tightness can be achieved?
The Table 4-6-2 summarizes expert opinions on the hydraulic conductivity that can be
achieved by cement grouting.
By testing the sensitivity of parameters in Equation 3-1 in Section 3.1 (c.f. the last row
in Table 4-6-1) it is evident that seepage is very dependent on the skin -value for
tunnels close to the water table. The estimated tightness value is indicative only as the
seepage is averaged for a range of geological conditions.
4.6.2 Grouting procedures
Drilling
Experts start more and more to recommend split-spacing of boreholes, i.e. that grouting
is made in two rounds; the first is for sealing the major seepage. The second round holes
are drilled in between the previous holes as control holes and these holes are grouted
depending on the recorded water-loss measurements.
In poor rock it is difficult to drill longer holes than 20 m and shorter fans are
recommended.
Choice of grout
The use of extremely fine-grained cements (12 - 16 J..Lm) is complicated. The 30 J..Lm
range could be a good compromise. For high sealing efficiency chemical grouts are
needed. Besides the health aspects grout material with properties like Rhoca-Gil are
useful for grouting and possible alternatives should be explored. The tests with the
Senad technology and colloidal silica should be studied more in depth.
Choice of water-cement ratio
Experts have strong opinion on whether grouting should start with stable grouts or not.
Many practicing engineers favour starting with high water-cement ratio and then
decrease the w/c with time. However many think that such a practice should be
abolished without hesitation. It seems reasonable to start with high water-cement ratio
and by and by decrease the w/c in narrow fractures as the more viscous grout can push
the less viscous grout without fingering. In open fractures , it is reasonable to start with a
low w/c where the grout is stable.
58
Table 4-6-1. Overview of the cases.
Project Excavation Seepage requirement Main

period 1/min, 100 m Pre-grouting
materials
Bolmen 1975- 1985 9-42 SH-cement (128 j.lm)+
Tunnel bentonite
StabiloGrout
AspoHRL 1990- 1994 80 Degerhamn Grouting Cement
(grout spread < 5- 1Om) (64 ~-tm) + 15 % CaCl
Hallandsas 1992- 21 Cementa Ultrafin (16 j.lm) +
(for two tunnel tubes) SP/Groutaid/
Lundby 1994- 1997 0.5-2.5 Cementa Injekteringscement
Tunnel (per tunnel tube) (30 j.lm) + bentonite + SP
Sodra Lanken 1998- 2001 1-4 Cementa Injekteringscement
(30 Jlm) + SP
Table 4-6-2. Opinions on what tightness that can be achieved.
Tightness
Source Project Reference
(rnls)
Noteby AS Oslo > 2.510-9 (Rosell, 2000)
incl chemical grouting?
Electrowatt N.A. 110-"/ (Rosell, 2000)
Pusch Stripa 110-~ (Pusch, 1992)
Vagverket N.A. 0.5 10-7 - 1.510-7 (Vagverket, 1993)
Kutzner N.A. 0.510-7 - 510-7 (Kutzner, 1996)
Backblom Bolmen 110-7 - 110-~ (Backblom, 1986b)
(adjusted with grout
spread t = 10 m)
Backblom Sodra Lanken Ki- 510-~ m/s Eq 3-1 in Section 3.1,
Lundby (Skin 0- 5, indicative only
K = 10-7 - 10-8 m/s,
h = 20-30 m,
t= 10m, R= 5 m
Q = 1 - 8 1/min, 100 m)
Stille Several, ordinary Ki- 310-' m/s (Stille 2001)
cement grout
Grouting hole order
Grouting should start with holes having the largest seepage/water-loss.

59
Number of simultaneously grouted holes
In the complicated rock, holes should be grouted one by one in spite of the short-term
impact on advance rate.
Grouting pressure
Experience at e.g. Hallandsas shows no disadvantage with using as high pressures as

5 MPa over the ambient ground water pressure.
Refusal criteria for stopping of grouting
Several opinions exist. If pressure increases, the same w/c is used to maximum pressure.
If no pressure increase develops, the w/c is lowered by and by depending on grout take.
An internationally acclaimed method is to use the Grouting Intensity Number,
(Lombardi & Deere 1993), and (Brantberger.et al 2001). The GIN-value is pV where
p = grouting pressure at zero grout take and V = volume of grout at zero grout flow .
Grouting continues if p < Pmax; V< Vmax and for a constant product of pV. Example: At
Hallandsas the Pmax is suggested to 55 bar (5.5 MPa) and Vmax to 25 kg/m borehole and
the suggested GIN-value is .... 275 - 340.
Equipment
It has been difficult to reproduce laboratory data in field mixers for very fine cements.
The common equipment for mixing is the colloid mixer. Good dispersion is achieved,
but due to the high-energy input, temperature is increased that may start creation of
unwanted agglomerates.
Blasting
Experts do not agree on the importance of cautious blasting not to destroy the grouted
zone. To the author's opinion, careful blasting is essential, mostly in the tunnel floor
and the procedures at Lundby tunnel and Sodra Lanken should be honoured. However it
is more difficult to achieve smooth blasting in a declining ramp as more energy is
needed to lift the rock debris out of from the tunnel face.
Procedures for showing compliance
When only minor seepage is permissible it is difficult to show compliance during the
period of construction. Clients have experienced problems with installations of
measurement weirs as they are not constructed in due time. It is also very difficult to
measure small seepage and deduct the production water, leaking temporary pipes and
valves.
61
5 DECREASE OF SEEPAGE WITH TIME- FIELD DATA
It has been observed that seepage decrease with time for quite a few underground
facilities, c.f. Table 5-1 . The table summarizes data for a few underground facilities in
Canada, Finland and Sweden. Decrease in seepage is in the order of 0.3 - 1.1 % per
month. For the cases referred to in Table 5-1 several explanations are offered for the
decrease, like precipitation of calcite and/or bacteria, degassing and rock creep etc.
However, it is possible that the seepage at SFR, Aspo and Lovisa VLJ will level out in
the future, like at the URL. The Figure 5-1 shows e.g. the seepage to the Underground
Research Laboratory shaft during the 10 year period 1984 - 1994. There is first a
transient during 1986 when seepage is down to 20 m 3/day from 30 m3/day, and then
there is a slow decrease until it stabilizes around 10 m 3/day some 5 years after the
excavation was finished.
There are also underground facilities where there is no or very limited decrease in
seepage with time (Lundby Tunnel, Olkiluoto VLJ).
Table 5-l. Decrease in seepage for selected underground facilities.
Facility Seepage in 1/min at Seepage in 1/min at Decrease

a certain date a certain date 1/min, month
%per month
CANADA
URL (Davison 14 Vmin; 7 Vmin 0.2 1/min, month
etal.1995) Jan 1987 Jan 1991 1.0%/month
FINLAND
Lovisa VLJ 300 1/min 140 Vmin 3.3 1/min, month
(Anttila et Jan 1996 Jan 2000 1.1% /month
al. 2001)
SWEDEN
CLAB 56 1/min; J an 1987 321/min; Jan 1999 0.2 Vmin, month; 0.32 %
SFR 720 1/min; Jan 1988 400 1/min; Jan 2000 2.2 1/month; 0.31 %
ASPOHRL 2100 Vmin; Jan 1995 1490 1/min; J an 2000 10.1 Vmonth; o. 48 %
(Christiansson
et al 2001)
62
Excavate Main Shaft to 255 m I

I
I I
I . I
I
I
Excavate Vent Raise to 240 Level
- -r - - -- T-- --T-- -- T-- --
I
1
I
I
I
I
I
I
I I I I
I I I I
I I I I
I I I I
I I I I
I I I I I I I I
--r----r----r-- - -r - -- - T- - --~- - --~----~ -- --
1 I I I I I I I
I t I I I I I I
I t ( ) I I
: Excavate Ma1n Shaft to 443 m : :
I I I I I I I
I
____ f____ f____ f- (
I I I I I I I
Ex~vateve~t Rai~ to42o:Level
1 I
I
I
I
I
I
I
t
I
I
I
I
I
I
_._I ____ ._I ____ ._I ____ ,_t ____ ,_ ____ ,_____
I
I
I
I
I
I
I
I
I
I
I I
I
I
__
I
I
I
I _,~
I I I l I I I
I I I I I I I
I I I t I I I
I I I t I I I
I I I t I I I
! 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994
Date
Figure 5-L Seepage of groundwater to the URL shaft during the ten-year period
1984 - 1994 (Davison et al 1995).
63
6 CONCLUSIONS
This report summarizes results from recent Swedish research and development in
grouting and experience from grouting operations in tunnels over a range of geological
conditions and a range of sealing requirements.
The objectives of this particular study are to describe:

What minimum leakage that can be/has been achieved by grouting?
What grouting materials have been used?
Of special importance is experience from grouting work at greater depths >> 100 m.
Information of leakage reduction during operation was also to be discussed.
Some conclusions and remarks are offered in the following.
6.1 The reduction in tunnel water inflow by use of grouting technology
Grouting is a complicated engineering activity that should optimise grouting material

and grouting technology to the heterogeneous geological conditions for a range of
seepage requirements. Developments in R&D the recent decade provide a good basis
for understanding the process of cement grouting. Factors like bleed, separation,
filtration and penetration is explored. There are reasonably good models to estimate
grout take and grout spread. However the current status of R&D is not sufficient to fully
understand grouting in clay-rich rock that is deformable.
Alternative grout materials have been tested systematically. The uses of colloidal silica
or cement foam are interesting developments in progress.
6.2 What minimum leakage can be/has been achieved by grouting?
The grouted zone will be in the range of 10-7 to 10-9 m/s using a cementitious grout
material, the results being dependent on geological conditions, choice of cement and
methodology used. The inflow of ground water can be as low as around 1 llmin, 100
tunnel-m for a large cement-grouted tunnel (section area 100 m2) excavated some
10 - 50 metres below the water table. This would indicate a grouted zone in the order
510-9 m/s, but this is certainly no verified value.
6.3 What grouting materials have been used?
Several experts presently favour the Cementa Injekteringscement 30 !Jm. The more fine
cements create practical problems like creation of aggregates. The use of silica gels like
the StabiloGrout is not very much in use.
64
When ambient water pressures are high> 100 m, the early gelling is important so that
packers can be removed without the grout extruding the grout holes. The combinations
of low early yield strength for penetration and high strength for removal of packers calls
for use of accelerators. CaCh has been used as the accelerator at the Aspo HRL.
The mix of cement and chemical compounds is needed to really reduce the seepage.
Glyoxal is a useful component, but creates poor longevity. Acryl amides provide
excellent penetration but cannot be used, as it is a very noxious material.
6.4 Experience from high water pressures
Besides additional requirements on the grouting material, there are problems setting
packers at high pressures. In poor rock it could be needed to install steel casings to
mount the packers, c.f. the design at Aspo HRL. Also the drilling rig needs high-
pressure pumps for flushing; if not water flows through the drill rod into the machine
instead of the other way around.
6.5 Decrease of seepage with time
Data on ground water inflow to underground facilities shows a total inflow reduction in
the order of 0.3 - 1 %per month. The reasons for these reductions are not understood.
65
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Working Report 2002-18

SAATE TYORAPORTIN TARKASTAMISESTA JA HYVAKSYMISESTA

TILAUS: 9672/0 1/JPS, 9522/02/JPS

TYORAPORTTI: EXPERIENCES ON GROUTING TO LIMIT INFLOW TO

TEKIJA Goran Backblom Conrox, Taby, Sweden

TARKASTAJA Ursula Sievanen Saanio

Conrox, Taby, Svveden

Working Reports contain information on work in progress

The conclusions and viewpoints presented in the report

The objectives of this particular study are !O describe:

Of special importance is experience from grouting work at greater depths

Data on groundwater inflow to underground facilities shows a total inflow reduction in

Keywords: Grouting, Bolmen, Aspo Hard Rock Laboratory, Hallandsas, Lundby,

Tassa raportissa kasitellaan viimeaikaista tutkimus- ja kehitystyota Ruotsissa

Tyon tavoitteena on kuvata:

Erityista huomiota on kiinnitetty injektointikokemuksiin syvista kalliotiloista

Viimeaikainen kehitys- ja tutkimustyo luo hyvan pohjan ymmartaa sementti-

Sementti-injektoinnilla paastaan vedenjohtavuusarvoihin K = 10-7 - 10-9 m/s.

Useat asiantuntijat eivat suosi liian hienorakeisten injektointisementtien kayttoa.

Suurten vesipaineiden vallitessa erityisia teknisia ongelmia voi aiheutua

Muutamassa kohteessa kalliotiloihin tulevien vesivuotojen havaittiin tyypillisesti

Avainsanat: Injektointi, Bolmen, Aspo kalliolaboratorio, Hallandsas, Lundby,

TABLE OF CONTENTS ..................................................................................... 1

2 STATEMENT OF PROBLEMS ............................................................ ...... 5

3 PRESENT UNDERSTANDING OF GROUTING ............... .. .. ..................... 9

4 CASE-STUDIES REVISITED ............ ....... ...... ...... .. .................................. 23

4.3 The Hallandsasen Railway Tunnel ..................... ............ .... ............. 37

5 DECREASE OF SEEPAGE WITH TIME- FIELD DATA ......................... 61

6 CONCLUSIONS ............................................ ........................................... 63

This study is conducted to compile experience on:

Banverket, Kenneth Rosell

This chapter present an outline of problems to be solved by grouting. Inflow should be

The problems are outlined in the following.

h =the depth of the interface below sea level (m),

2.2 Mineralogical changes in fractures due to inflow affecting oxygen

2.3 Smooth deposition and backfilling

The smooth deposition and backfilling operation is very essential as unforeseen

2.4 Safe installation of rock support

2.5 Environmental effects of the drawdown of the water table

2.6 Diversion of pumped groundwater

2.7 Cost of handling water

2.8 Impacts during pre-closure operation

Grouting is useful to minimize the problems addressed here.

3 PRESENT UNDERSTANDING OF GROUTING

3.1 Inflow to a tunnel

Figure 3-1-1. Conceptual model for inflow to a deep, grouted tunnel.

Q =inflow to the tunnel per metre of tunnel (m3/s, m),

The effect of grouting is now illustrated for a choice of parameters to receive a

Skin factor Inflow Q to tunnel

RADIUS Inflow Q to tunnel

Conductivity Ki for Inflow Q to tunnel

It is obvious that the achieved hydraulic conductivity by grouting is much more

There is a common definition for the sealing efficiency Serf as

Inflow requirement after grouting

Hydraulic conductivity K Inflow Q to tunnel without Required sealing

Hydraulic conductivity K Inflow Q to tunnel with grouting

3.2 Geological factors

3.2.1 Strategy for rock characterisation

The following promising general conclusions in (Fransson 2001) are:

Scale Investigations/ Obtained parameters Influence on grouting strategy

Grouting Distribution of fracture lengths Distance between probe holes

Overview of the rock ahead of tunnel, initial

3.2.2 Important fracture properties

Fracture K before 90 % reduction K (90%) 99 % reduction K (99%)